Body

5-1 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Precaution
1. Precaution
A: SUPPLEMENTAL RESTRAINT
SYSTEM “AIRBAG”
Airbag system wiring harness is routed on and
along body panels.
CAUTION:
I All Airbag system wiring harness and connec-
tors are colored yellow. Do not use electrical test
equipment on these circuit.
I Be careful not to damage Airbag system wiring
harness when repairing the body panel.
2
SPECIFICATIONS AND SERVICE DATA [S2A1] 5-1
2. Body Datum Points

Various master repair locations are established as datum points used during body repairs. In addition, guide
holes, locators and indents are provided to facilitate panel replacement and achieve alignment accuracy.
NOTE:
Left and right datum points are all symmetrical to each other.
A: ENGINE COMPARTMENT AND ROOM
1. SEDAN AND WAGON
H5M0815A
3
(1) Radiator panel (UPR) repair bolt (10) Hood hinge attaching bolt hole (20) Center pillar gauge hole 10 mm
hole M8 (Right) M8 (Symmetrical) (0.39 in) dia. (Symmetrical)
(2) Radiator panel (UPR) repair bolt (11) Cowl panel mounting hole 5 mm (21) Belt anchor attaching bolt hole
hole M8 (Left) (0.20 in) dia. (Located in center (Symmetrical)
(3) Fender attaching bolt hole M6 of vehicle.) (22) Wax coat hole, 20 mm (0.79 in)
(Symmetrical) (12) Front rail (Inner) mirror attaching dia. (Symmetrical)
(4) Headlight attaching bolt hole M6 bolt hole 8 mm (0.31 in) dia. (23) Rear door switch attaching hole
(Symmetrical) (13) Fender attaching bolt hole M6 20 mm (0.79 in) dia. (Symmetri-
(5) Radiator panel side gauge hole (Symmetrical) cal)
24 mm (0.94 in) dia. (Symmetri- (14) Front pillar gauge hole 20 mm (24) Retainer attaching square hole 7
cal) (0.79 in) dia. (Symmetrical) mm (0.28 in) (Symmetrical)
(6) Front bumper mounting hole 14 (15) Wax coat hole, 20 mm (0.79 in) (25) Spare tire attaching bolt hole M8
x 17 mm (0.55 x 0.67 in) dia. dia. (Symmetrical) (26) Air draw hole 7 mm (0.28 in) dia.
(Symmetrical) (16) Retainer attaching square hole 7 (Symmetrical)
(7) Front crossmember attaching mm (0.28 in) (Symmetrical) (60) Fender attaching bolt hole M6
bolt hole 12.4 mm (0.488 in) dia. (17) Sun visor attaching hole 20 mm (Symmetrical)
(Symmetrical) (0.79 in) dia. (Symmetrical) (64) Door switch attaching hole 20
(8) Fender attaching bolt hole M6 (18) Retainer attaching square hole 7 mm (0.79 in) dia. (Symmetrical)
(Symmetrical) mm (0.28 in) (Symmetrical) (67) Front glass attaching hole Right
(9) Front strut mounting hole 10 mm (19) Retainer attaching square hole 7 6.5 mm (0.256 in) dia. Left 6.5 x
(0.39 in) dia. (Symmetrical) mm (0.28 in) (Symmetrical) 10 mm (0.256 x 0.39 in) dia.
4
SPECIFICATIONS AND SERVICE DATA [S2A2] 5-1
2. COUPE
H5M0712B
5
(1) Radiator panel (UPR) repair bolt (11) Cowl panel mounting hole 5 mm (70) Door switch attaching hole 13.5
hole M8 (Right) (0.20 in) dia. (Located in center mm (0.531 in) dia. (Symmetrical)
(2) Radiator panel (UPR) repair bolt of vehicle.) (71) Retainer attaching square hole 8
hole M8 (Left) (12) Front rail (Inner) mirror attaching mm (0.31 in). (Symmetrical)
(3) Fender attaching bolt hole M6 bolt hole 8 mm (0.31 in) dia. (72) Rear quarter glass attaching
(Symmetrical) (13) Fender attaching bolt hole M6 hole 8 mm (0.31 in) dia. (Sym-
(4) Headlight attaching bolt hole M6 (Symmetrical) metrical)
(Symmetrical) (14) Front pillar gauge hole 20 mm (73) Rear quarter glass attaching
(5) Radiator panel side gauge hole (0.79 in) dia. (Symmetrical) hole 7 mm (0.28 in) dia. (Sym-
24 mm (0.94 in) dia. (Symmetri- (16) Retainer attaching square hole 7 metrical)
cal) mm (0.28 in) (Symmetrical) (74) Rear quarter glass attaching
(6) Front bumper mounting hole 14 (17) Sun visor attaching hole 20 mm hole 8 x 5.5 mm (0.31 x 0.217
x 17 mm (0.55 x 0.67 in) dia. (0.79 in) dia. (Symmetrical) in) dia. (Symmetrical)
(Symmetrical) (25) Spare tire attaching bolt hole M8 (75) Retainer attaching square hole 8
(7) Front crossmember attaching (26) Air draw hole 7 mm (0.28 in) dia. mm (0.31 in). (Symmetrical)
bolt hole 12.4 mm (0.488 in) dia. (Symmetrical) (76) Seat belt anchor attaching bolt
(Symmetrical) (60) Fender attaching bolt hole M6 hole 16 mm (0.63 in) dia. (Sym-
(8) Fender attaching bolt hole M6 (Symmetrical) metrical)
(Symmetrical) (67) Front glass attaching hole Right
(9) Front strut mounting hole 10 mm 6.5 mm (0.256 in) dia. Left 6.5 x
(0.39 in) dia. (Symmetrical) 10 mm (0.256 x 0.39 in) dia.
(10) Hood hinge attaching bolt hole (69) Wax coat hole 20 mm (0.79 in)
M8 (Symmetrical) dia. (Symmetrical)
6
SPECIFICATIONS AND SERVICE DATA [S2B1] 5-1
B: LUGGAGE COMPARTMENT AND ROOM

1. SEDAN AND COUPE
H5M0816A
7
5-1 [S2B1] SPECIFICATIONS AND SERVICE DATA
(27) Rear pillar (Inner) gauge hole 8 (33) Rear skirt (UPR) cutout (Repair (39) Steering support beam attaching
mm (0.31 in) dia. (Symmetrical) locator) bolt hole M8 (Symmetrical)
(28) Rear roof trim attaching hole 8 (34) Rear skirt gauge hole 20 mm (40) Front pillar (Inner) gauge hole 10
mm (0.31 in) dia. (Symmetrical) (0.79 in) dia. (Symmetrical) mm (0.39 in) dia. (Symmetrical)
(29) Rear quarter trim attaching hole (35) Rear combination light mounting (41) Floor mat attaching clip hole 8
8 mm (0.31 in) dia. (Symmetri- hole 9 mm (0.35 in) dia. (Sym- mm (0.31 in) dia. (Symmetrical)
cal) metrical) (66) Rear panel (Center) repair loca-
(30) Seat belt anchor attaching bolt (36) Rear quarter bumper side gauge tor (Located in center of vehicle.)
hole (Symmetrical) hole 20 mm (0.79 in) dia. (Left) (68) Rear glass attaching hole
(31) Reinforcement (Rear panel rear) (37) Rear quarter bumper side gauge (Right): 6.5 mm (0.256 in) dia.
repair locator (Located in center hole 20 mm (0.79 in) dia. (Right) (Left): 6.5 x 10 mm (0.256 x 0.39
of vehicle) (38) Instrument panel attaching in) dia.
(32) Rear corner patch at flange square hole 22 x 34.5 mm (0.87
(Symmetrical) x 1.358 in) (Right)
8
2. WAGON
H5M0817A
(42) Rear quarter glass attaching (46) Rear strut mounting hole 10 mm (61) Side rail (Inner) gauge hole 8
hole 8 mm (0.31 in) dia. (Sym- (0.39 in) dia. (Symmetrical) mm (0.31 in) dia. (Symmetrical)
metrical) (47) Rear gate stay attaching bolt (62) Rear quarter trim attaching hole
(43) Roof rail attaching hole 10 mm hole M8 (Symmetrical) 8 mm (0.31 in) dia. (Symmetri-
(0.39 in) dia. (Symmetrical) (48) Child seat anchor attaching bolt cal)
(44) Rear quarter glass attaching hole (63) Rear quarter harness attaching
hole 8 x 15 mm (0.31 x 0.59 in) (49) Rear combination light mounting clip hole 7 mm (0.28 in) dia.
dia. (Symmetrical) hole 10 mm (0.39 in) dia. (Sym- (Symmetrical)
(45) Rear roof trim attaching hole 8 metrical) (65) Seat belt anchor attaching bolt
mm (0.31 in) dia. (Symmetrical) hole (Symmetrical)
9
5-1 [S2C0] SPECIFICATIONS AND SERVICE DATA
C: UNDER BODY
H5M0818A
(50) Radiator panel (LWR) frame (53) Front suspension attaching bolt (57) Rear differential attaching bolt
gauge hole 15 mm (0.59 in) dia. hole M14 hole M12 (Symmetrical)
(Symmetrical) (54) Side frame gauge hole 20 mm (58) Rear suspension attaching bolt
(51) Front side frame gauge hole 20 (0.79 in) dia. (Symmetrical) hole M12 (Symmetrical)
mm (0.79 in) dia. (Symmetrical) (55) Transmission mount attaching (59) Rear side frame gauge hole 15
(52) Front crossmember attaching bolt hole M10 (Symmetrical) mm (0.59 in) dia. (Symmetrical)
hole 12.4 mm (0.488 in) dia. (56) Side frame gauge hole 15 mm
(Symmetrical) (0.59 in) dia. (Symmetrical)
10
SPECIFICATIONS AND SERVICE DATA [S2D0] 5-1
D: DATUM POINT LOCATION
H5M0819A H5M0823A
H5M0820A
H5M0824A
H5M0825A
H5M0821A
H5M0822A H5M0826A
11
5-1 [S2D0] SPECIFICATIONS AND SERVICE DATA
H5M0827A H5M0831A
H5M0828A
H5M0832A
H5M0833A
H5M0829A
H5M0830A
H5M0834A
12
H5M0835A
H5M0839A
H5M0836A H5M0840A
H5M0841A
H5M0837A
H5M0842A
H5M0838A
13
H5M0847A
H5M0843A
H5M0848A
H5M0844A
H5M0845A
H5M0849A
H5M0846A H5M0850A
14
H5M0851A
H5M0855A
H5M0852A H5M0856A
H5M0857A
H5M0853A
H5M0854A H5M0858A
15
H5M0859A
H5M0863A
H5M0860A H5M0864A
H5M0861A H5M0865A
H5M0866A
H5M0862A
16
H5M0871A
H5M0867A
H5M0868A
H5M0872A
H5M0869A
H5M0873A
H5M0870A H5M0874A
17
H5M0875A
H5M0879A
H5M0876A H5M0880A
H5M0881A
H5M0670B
H5M0878A H5M0882A
18
H5M0883A H5M0887A
H5M0888A
H5M0884A
H5M0885A
H5M0889A
H5M0886A
19
5-1 [S300] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
3. Datum Dimensions NOTE:

I A suffix character “R” or “L” refers to the right or
Use a tram tracking gauge to measure all dimen- the left.
sions. If a measuring tape is used, be extremely I All dimensions refer to the distance between the
careful because it tends to deflect or twist, which centers of holes measured in a straight line
results in a false reading. I Each dimension indicates a projected dimension
between hole centers.
G5M0122
A: FRONT STRUCTURE
H5M0890A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) to (9) R 525 (20.67) (10) R to (10) L 1,382 (54.41)
(11) to (9) L 525 (20.67) (3) R to (3) L 1,336 (52.60)
(11) to (6) R 988 (38.90) (5) R to (5) L 942 (37.09)
(11) to (6) L 988 (38.90) (5) R to (4) R 1,174 (46.22)
(11) to (3) R 990 (38.98) (5) L to (4) L 1,174 (46.22)
(11) to (3) L 990 (38.98) (4) R to (4) L 1,269 (49.96)
(10) R to (3) R 829 (32.64) (60) R to (13) R 1,113 (43.82)
(10) L to (3) L 829 (32.64) (60) L to (13) L 1,113 (43.82)
(10) R to (8) R 567 (22.32) (60) R to (14) R 1,076 (42.36)
(10) L to (8) L 567 (22.32) (60) L to (14) L 1,076 (42.36)
(8) R to (3) R 264 (10.39) (1) to (11) 882 (34.72)
(8) L to (3) L 264 (10.39) (2) to (11) 913 (35.94)
20
3. Datum Dimensions
B: CENTER STRUCTURE
H5M0891A
21
5-1 [S3C1] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
C: DOORS AND REAR QUARTER

1. SEDAN AND WAGON
H5M0892A
Unit: mm (in)
(14) to (18) 1,495 (58.86) (19) to (23) 912 (35.91)
(13) to (64) 947 (37.28) (20) to (36) L* 1,462 (57.56)
(16) to (64) 976 (38.43) (20) R to (37) R* 1,481 (58.31)
(20) to (23) 803 (31.61) (62) to (43) * 377 (14.84)
(20) to (24) 829 (32.64) (42) to (44) * 847 (33.35)
*: Wagon only
22
SPECIFICATIONS AND SERVICE DATA [S3C2] 5-1
3. Datum Dimensions
2. COUPE
H5M0713B
Unit: mm (in)
(14) to (71) 1,576 (62.05) (72) to (74) 778 (30.63)
(13) to (70) 1,251 (49.25) (73) to (75) 512 (20.16)
(16) to (70) 997 (39.25) (70) to (36) L 1,295 (50.98)
(13) to (69) 1,063 (41.85) (70) to (37) R 1,243 (48.94)
23
3. Datum Dimensions
D: FRONT WINDSHIELD AND REAR WINDOW
H5M0893A
Unit: mm (in)
(11) to (12) 989 (38.94) (66) to (28) L 714 (28.11)
(67) R to (67) L 1,012 (39.84) (66) to (68) R 856 (33.70)
(11) to (67) R 1,116 (43.94) (66) to (68) L 856 (33.70)
(11) to (67) L 1,116 (43.94) (68) R to (68) L 1,012 (39.84)
(66) to (28) R 714 (28.11)
24
SPECIFICATIONS AND SERVICE DATA [S3E0] 5-1
3. Datum Dimensions
E: TRUNK LID AND REAR GATE
H5M0894A
Unit: mm (in)
(31) to (32) R 575 (22.64) (35) R to (35) L 1,364 (53.70)
(31) to (32) L 575 (22.64) (45) R to (48) 988 (38.90)
(31) to (26) R 812 (31.97) (45) L to (48) 988 (38.90)
(31) to (26) L 812 (31.97) (45) R to (47) R 926 (36.46)
(31) to (33) 522 (20.55) (45) L to (47) L 926 (36.46)
(31) to (35) R 794 (31.26) (47) R to (47) L 1,043 (41.06)
(31) to (35) L 794 (31.26) (49) R to (49) L 1,355 (52.56)
(34) R to (34)L 890 (35.04) (34) R to (34) L 890 (35.04)
25
5-1 [S3F0] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
F: COMPARTMENT
H5M0895A
Unit: mm (in)
Point to point Dimension Point to point Dimension Point to point Dimension
(30) R to (30) L 1,197 (47.13) (41) to (15) R 1,140 (44.88) (41) to (30) L* 1,168 (45.98)
(21) R to (21) L 1,061 (41.77) (41) to (15) L 1,140 (44.88) (41) to (28) R* 1,050 (41.34)
(15) R to (15) L 1,453 (57.20) (41) to (22) R 733 (28.86) (41) to (28) L* 1,050 (41.34)
(22) R to (22) L 1,453 (57.20) (41) to (22) L 733 (28.86) (41) to (21) R 1,038 (40.87)
(39) R to (39) L 1,388 (54.65) (41) to (12) 1,156 (45.51) (41) to (21) L 1,038 (40.87)
(40) R to (40) L 1,401 (55.16) (41) to (27) R 1,085 (42.72) (41) to (17) R 1,208 (47.56)
(41) to (38) 1,527 (60.12) (41) to (27) L 1,085 (42.72) (41) to (17) L 1,208 (47.56)
(41) to (39) R 1,524 (60.00) (41) to (26) R 1,568 (61.73) (41) to (33) * 1,569 (61.77)
(41) to (39) L 1,524 (60.00) (41) to (26) L 1,568 (61.73) (76) R to (76) 1,212 (47.72)
L✩
(41) to (40) R 1,756 (69.13) (41) to (25) 1,184 (46.61)
(41) to (40) L 1,756 (69.13) (41) to (30) R* 1,168 (45.98)
*: Sedan only ✩ : Coupe only
26
SPECIFICATIONS AND SERVICE DATA [S3G0] 5-1
3. Datum Dimensions
G: LUGGAGE ROOM
H5M0896A
Unit: mm (in)
(41) to (65) R 1,122 (44.17) (41) to (43) R 1,237 (48.70)
(41) to (65) L 1,122 (44.17) (41) to (43) L 1,237 (48.70)
(41) to (45) R 1,225 (48.23) (48) to (46) R 971 (38.23)
(41) to (45) L 1,225 (48.23) (48) to (46) L 971 (38.23)
(41) to (48) 1,446 (56.93) (65) R to (65) L 1,235 (48.62)
27
5-1 [S400] SPECIFICATIONS AND SERVICE DATA
4. Datum Points and Dimensions Concerning On-Board Aiming Adjustment
4. Datum Points and Dimensions Concerning On-Board Aiming

Adjustment
If headlight aiming is misaligned due to damaged body panel, repair headlight mating surface using body
and headlight datum points as a guide.
H5M0898A
Unit: mm (in)
(11) to (A) L 993 (39.09) (11) to (B) L 1,048 (41.26)
(11) to (A) R 993 (39.09) (11) to (B) R 1,048 (41.26)
28
COMPONENT PARTS [C100] 5-1
1. Front Hood and Hood Lock
1. Front Hood and Hood Lock
H5M0671B
(1) Front hood (7) Hood lock ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Hinge (RH, LH) (8) Striker
T1: 14±9 (1.4±0.9, 10.1±6.5)
(3) Hood hinge cover (RH, LH) (9) Front hood stay
T2: 32±1 (3.3±0.1, 23.9±0.7)
(4) Lever ASSY (10) Seal (Front hood) SD
(5) Cable (11) Seal (Front hood) CTR
(6) Stopper
29
5-1 [C200] COMPONENT PARTS
2. Trunk Lid
2. Trunk Lid
H5M0900A
(1) Torsion bar (5) Trunk lid lock ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Trunk lid (6) Striker
T1: 14±4 (1.4±0.4, 10.1±2.9)
(3) Weatherstrip (7) Hinge ASSY
T2: 18±5 (1.8±0.5, 13.0±3.6)
(4) Rod
30
3. Front Bumper
3. Front Bumper
H5M0938A
(1) Plate (5) Front beam (Except USA 2500 (9) Bumper face (USA 2500 cc)
(2) Bumper face (Except USA 2500 cc)
cc) (6) Bracket (Side) Tightening torque: N·m (kg-m, ft-lb)
(3) Spacer (7) Holder upper T: 93±25 (9.5±2.5, 69±18)
(4) E/A form bumper (8) Front beam (USA 2500 cc)
31
4. Rear Bumper
4. Rear Bumper
H5M0715B
(1) Holder upper (4) E/A from bumper Tightening torque: N·m (kg-m, ft-lb)
(2) Bumper beam (5) Plate
T: 93±25 (9.5±2.5, 69±18)
(3) Bracket (Side) (6) Bumper surface
32
5. Sunroof
5. Sunroof
H5M0901A
(1) Weatherstrip (10) Harness (19) Shutting ASSY (RH)

(2) Sunroof panel (11) Sunroof trim (20) Shutting ASSY (LH)
(3) Rear guide ASSY (12) Guide rail (21) Drain tube
(4) Lower panel (13) Set bracket (22) Garnish
(5) Lower panel (14) Guide rail
(6) Rear guide ASSY (15) Motor ASSY Tightening torque: N·m (kg-m, ft-lb)
(7) Drive unit (16) Sealed tape T: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(8) Relay (17) Frame ASSY
(9) Harness (18) Sealed cushion
33
6. Steering Support Beam
6. Steering Support Beam
H5M0902A
(1) Bracket Tightening torque: N·m (kg-m, ft-lb)

(2) Steering beam
T: 18±5 (1.8±0.5, 13.0±3.6)
34
7. Guard Pipe
7. Guard Pipe
B5M0371C
(1) Guard pipe Tightening torque: N·m (kg-m, ft-lb)

(2) Rear floor panel
T: 32±10 (3.3±1.0, 23.9±7)
35
5-1 [W1A0] SERVICE PROCEDURE
1. Hood
1. Hood 2) Remove bolts which secure lock assembly to

radiator panel, and remove lock assembly.
A: REMOVAL AND INSTALLATION
NOTE:
The hood lock has a dual locking design which
consists of a main lock and a safety lock mecha-
nism. When the release knob located at the front
pillar on the driver’s side is pulled back, the main
lock is released through the cable attached to the
knob.
The safety lock can be released by pushing the
lever protruding above the front grill while opening
G5M0138
the hood.
1. HOOD 3) Disconnect release cable from lock assembly
4) Installation is in the reverse order of removal.
1) Open front hood, and remove washer hose.
2) Remove attaching bolts. NOTE:
I Route hood lock release cable and hold with
clips.
I After installing release cable, ensure it operates
smoothly.
I Apply grease to sliding surfaces of parts.
G5M0137
3) Detach front hood from hinges.

CAUTION: G5M0142
Adjust buffer assembly on each end so that
main lock is applied securely when hood is 3. RELEASE CABLE
released from a height of approx. 20 mm (0.79
in). 1) Remove front grille.
2) Remove release cable from lock assembly.
NOTE: 3) Remove cable clip from engine compartment.
Align the center of striker with lock during installa- 4) Remove bracket from front pillar.
tion. Make sure safety lever is properly caught by
striker under the hood’s own weight.
G5M0139
G5M0141
B: POINTS TO CHECK
2. HOOD LOCK
1) Check striker for bending or abnormal wear.
1) Open front hood and remove front grille. 2) Check safety lever for improper movement.
36
SERVICE PROCEDURE [W2A3] 5-1
2. Trunk Lid
3) Check other levers and spring for rust formation 2. Trunk Lid
and unsmooth movement.
1. TRUNK LID
1) Open trunk lid.
2) Remove trunk lid mounting bolts and detach
trunk lid from hinges.
G5M0140
C: ADJUSTMENT
1) Fore-aft and left-right adjustments Loosen
striker mounting bolts and adjust fore-and-aft posi-
tion of striker. G5M0144
CAUTION:
Do not adjust striker position using the lock.
Doing so may result in a misaligned front grille. 2. TORSION BAR
1) Open trunk lid. Remove torsion bars from hinge
links using ST.
ST 927780000 REMOVER
CAUTION:
Be careful because torsion bar quickly swings
back when released.
G5M0145
2) Remove the left and right torsion bars.

WARNING:
G5M0143 Be careful because trunk lid drops under its
own weight when torsion bars are removed.
2) Up-down adjustment
Make up-and-down adjustment of striker only 3) Installation is in the reverse order of removal.
when hood does not properly contact buffer or NOTE:
hood is not flush with fender, or when release cable
Apply a coat of grease to the rotary section of
does not properly operate. Adjustment can be
hinges and contact surfaces of torsion bars.
made by adjusting the stroke length of striker after
lock assembly mounting screws are removed. 3. TRUNK LID LOCK ASSEMBLY AND
KEY CYLINDER
1) Remove rod of lock assembly from rod holder
of key lock assembly.
37
2. Trunk Lid
3) Check other levers and spring for rust formation 2. Trunk Lid
and unsmooth movement.
1. TRUNK LID
1) Open trunk lid.
2) Remove trunk lid mounting bolts and detach
trunk lid from hinges.
G5M0140
C: ADJUSTMENT
1) Fore-aft and left-right adjustments Loosen
striker mounting bolts and adjust fore-and-aft posi-
tion of striker. G5M0144
CAUTION:
Do not adjust striker position using the lock.
Doing so may result in a misaligned front grille. 2. TORSION BAR
1) Open trunk lid. Remove torsion bars from hinge
links using ST.
ST 927780000 REMOVER
CAUTION:
Be careful because torsion bar quickly swings
back when released.
G5M0145
2) Remove the left and right torsion bars.

WARNING:
G5M0143 Be careful because trunk lid drops under its
own weight when torsion bars are removed.
2) Up-down adjustment
Make up-and-down adjustment of striker only 3) Installation is in the reverse order of removal.
when hood does not properly contact buffer or NOTE:
hood is not flush with fender, or when release cable
Apply a coat of grease to the rotary section of
does not properly operate. Adjustment can be
hinges and contact surfaces of torsion bars.
made by adjusting the stroke length of striker after
lock assembly mounting screws are removed. 3. TRUNK LID LOCK ASSEMBLY AND
KEY CYLINDER
1) Remove rod of lock assembly from rod holder
of key lock assembly.
37
2. Trunk Lid
2) Remove bolts which hold lock assembly and 7) Disconnect cable from striker.
remove lock assembly. NOTE:
NOTE: Be careful not to bend or break cable.
I Always remove rear skirt trim panel beforehand,
if so equipped.
I Be careful not to bend opener cable.
G5M0147

G5M0146 CAUTION:
I When installing cover to pull handle
3) Remove clip and detach key cylinder from trunk assembly, observe the following:
I Be careful not to catch harness.
lid.
I Engage pull handle assembly pawls
firmly.
NOTE: NOTE:
Apply grease to sliding surfaces of lock assembly After installing opener cable, ensure it moves
and striker. smoothly.
B: ADJUSTMENT
1. TRUNK LID
1) To adjust left-right lid positioning, loosen bolts
which hold trunk lid to hinges.
2) To adjust up-down lid alignment, place wash-
er(s) between trunk lid and hinges or move trunk
lock assembly up or down.
G5M0148
4. TRUNK LID OPENER

1) Remove driver’s seat, rear seats, center pillar
lower cover, floor mat, rear arch cover and side sill
cover (on the driver’s side).
2) Remove all clips which hold cable.
3) Disconnect cable from pull handle assembly.
4) Remove bolts and detach pull handle assembly. G5M0149
5) Loosen bolts which hold lock assembly, and
remove it.
6) Remove striker from trunk lid.
38
4. Front Bumper
3. Fuel Flap 4. Front Bumper

A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION
1. FUEL FLAP 1) Disconnect the ground cable from the battery.
1) Remove bolts which hold hinge to car body, and 2) Remove the canister.
detach fuel flap and hinge as a unit. 3) Remove the front grille.
4) Remove the parking light and headlight LH.
5) Remove the mud guard.
6) Remove bolts from side of bumper.
G5M0150

CAUTION: G5M0152
Make sure the clearance between fuel flap and
car body is equal at all points. 7) Remove bolt from lower center of bumper.
2. FUEL FLAP OPENER

lower cover, floor mat, rear arch cover/rear quarter
trim (wagon), and side sill cover (on the driver’s
side).
3) Disconnect cable from pull handle.
4) Detach pull handle by removing bolts.
H5M0717
8) Remove bolts from lower side of bumper.
G5M0151
5) Detach fuel lock holder by turning it.

CAUTION: G5M0154
assembly, observe the following:
firmly.
I After installing opener cable, ensure it
moves smoothly.
39
4. Front Bumper
3. Fuel Flap 4. Front Bumper

1. FUEL FLAP 1) Disconnect the ground cable from the battery.
1) Remove bolts which hold hinge to car body, and 2) Remove the canister.
detach fuel flap and hinge as a unit. 3) Remove the front grille.
4) Remove the parking light and headlight LH.
5) Remove the mud guard.
G5M0150

CAUTION: G5M0152
Make sure the clearance between fuel flap and
car body is equal at all points. 7) Remove bolt from lower center of bumper.
2. FUEL FLAP OPENER

lower cover, floor mat, rear arch cover/rear quarter
trim (wagon), and side sill cover (on the driver’s
side).
3) Disconnect cable from pull handle.
4) Detach pull handle by removing bolts.
H5M0717
8) Remove bolts from lower side of bumper.
G5M0151
5) Detach fuel lock holder by turning it.

CAUTION: G5M0154
assembly, observe the following:
firmly.
I After installing opener cable, ensure it
moves smoothly.
39
5. Rear Bumper
9) Remove bolts (engine compartment side) from 5. Rear Bumper

bumper stays.
1. SEDAN
1) Open trunk lid. Remove trunk trim panel clips
and detach trim.
2) Disconnect license plate light connector.
G5M0156
10) Remove turn signal light connector.

11) Remove bumper assembly.
G5M0160
4) Remove bolts from bumper stay.
G5M0157

CAUTION:
I Be extremely careful to prevent scratches on
bumper face as it is made of resin.
I Be careful not to scratch the body when
G5M0161
removing or installing the bumper.
I When installing canister, insert air vent hose 5) Remove rear bumper.
of canister into the hole on body.
NOTE:
To facilitate installation of front bumper, attach
hook (located at stay) to body panel.
G5M0162
G5M0158
40
5. Rear Bumper
9) Remove bolts (engine compartment side) from 5. Rear Bumper

bumper stays.
1. SEDAN
1) Open trunk lid. Remove trunk trim panel clips
and detach trim.
G5M0156
10) Remove turn signal light connector.

G5M0160
4) Remove bolts from bumper stay.
G5M0157

CAUTION:
I Be extremely careful to prevent scratches on
bumper face as it is made of resin.
I Be careful not to scratch the body when
G5M0161
removing or installing the bumper.
I When installing canister, insert air vent hose 5) Remove rear bumper.
of canister into the hole on body.
NOTE:
To facilitate installation of front bumper, attach
hook (located at stay) to body panel.
G5M0162
G5M0158
40
5. Rear Bumper
6) Installation is in the reverse order of removal. 6) Installation is in the reverse order of removal.
CAUTION: CAUTION:
I Be extremely careful to prevent scratches on I Be extremely careful to prevent scratches on
bumper face as it is made of resin. bumper face as it is made of resin.
I Be careful not to scratch the body when I Be careful not to scratch the body when
removing or installing bumper. removing or installing bumper.
NOTE: NOTE:
To facilitate installation of rear bumper, attach hook To facilitate installation of rear bumper, attach hook
(located at stay) to body panel. (located at stay) to body panel.
G5M0163
G5M0163
2. WAGON
1) Open rear gate and rear quarter trim lid.
4) Remove bolts from bumper stays.
41
6. Coating Method for PP Bumper
6. Coating Method for PP

Bumper
A: PROCESS STEPS
Process No. Process name Job contents
1 Bumper mounting Set bumper on paint worktable if required.
Use paint worktable conforming to inner
shape of bumper when possible.
G5M0164
2 Masking Mask specified part (black base) with masking tape. Use masking tape for PP
(example, Nichiban No. 533, etc.).
3 Degreasing, cleaning Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt,
oil, fat, etc.
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
5 Drying Dry at normal temperature [10 to 15 min. at 20°C (68°F)]. In half-dried condition, PP
primer paint is dissolved by solvent, e.g. thinner, etc. Therefore, if dust or dirt must be
removed, use ordinary alcohol, etc.
6 Top coat paint (I) Solid color Metallic color
Use section (block) paint for top coat. Use section (block) paint for top coat.
I Paint in use (for each color): I Paint in use (for each color):
Solid paint Metallic paint
Hardener PB Hardener PB
Thinner T-301 Thinner T-306
I Mixing ratio: Main agent vs. hardener = I Mixing ratio: Main agent vs. hardener
4:1 = 10:1
I Viscosity: 10 — 13 sec/20°C (68°F) I Viscosity: 10 — 13 sec/20°C (68°F)
I Film thickness: 35 — 45µ I Film thickness: 15 — 20µ
I Spraying pressure: 245 — 343 kPa (2.5 I Spraying pressure: 245 — 343 kPa
— 3.5 kg/cm2, 36 — 50 psi) (2.5 — 3.5 kg/cm2, 36 — 50 psi)
7 Drying Not required. Dry at normal temperature [10 min. or
more at 20°C (68°F)]. In half-dried
condition, avoid dust, dirt.
8 Top coat paint (II) Not required. Apply a clear coat to parts with top coat
paint (I), three times, at 5 — 7 minute
intervals.
I Paint in use
Metallic paint
Hardener PB
Thinner T-301
I Mixing ratio: Clear vs. hardener = 6:1
I Viscosity: 14 — 16 sec/20°C (68°F)
I Film thickness: 25 — 30µ
I Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
9 Drying 60°C (140°F), 60 min. or 80°C (176°F), 30 min. If higher than 80°C (176°F), PP may
be deformed. Keep maximum temperature of 80°C (176°F).
10 Inspection Paint check.
11 Masking removal Remove masking in process No. 2.
42
SERVICE PROCEDURE [W7C0] 5-1
7. Repair Instructions for Colored PP Bumper

All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be
restored to its former condition. Damage limited to shallow scratches that cause only a change in the lus-
tre of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain
this point to the customer and get an understanding about the matter. Repair methods are outlined below,
based on a classification of the extent of damage.
A: MINOR DAMAGE CAUSING ONLY A CHANGE IN THE LUSTRE OF THE

BUMPER DUE TO A LIGHT TOUCH
Almost restorable.
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the repairing area with #500 sandpaper in a “feathering” motion.
3 Finish Resin section Coated section
Repeatedly apply wax to the affected Perform either the same operation as for
area using a soft cloth (such as flan- the resin section or process No. 18 and
nel). subsequent operations in the “(3)”
Recommended wax: NITTO KASEI section, depending on the degree and
Soft 99 TIRE WAX BLACK, or equiva- nature of damage.
lent.
Polish the waxed area with a clean
cloth after 5 to 10 minutes.
B: DEEP DAMAGE CAUSED BY SCRATCHING FENCES, ETC.

A dent cannot be repaired but a whitened or swelled part can be removed.
1 Cleaning Clean damaged area with water.
2 Removal of damaged Cut off protruding area, if any, due to collision, using a putty knife.
area
3 Sanding Grind the affected area with #100 to #500 sandpaper.
4 Finish Resin section Coated section
Same as Process No. 3 in the “(1)” Perform Process No. 12 and subsequent
section. operations in the “(3)” section.
C: DEEP DAMAGE SUCH AS A BREAK OR HOLE THAT REQUIRES FILLING

Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not
really worth the expense. (The surface, however, will become almost flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)
Process Process name Job contents
No.
1 Job contents Remove bumper as required.
2 Part removal Remove parts built into bumper as required.
3 Bumper placement Place bumper on a paint worktable
as required. It is recommended that
contour of worktable accommodate
internal shape of bumper.
G5M0164
4 Surface preparation Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a
suitable solvent (NRM No. 900 Precleno, white gasoline, or alcohol).
43
5-1 [W7C0] SERVICE PROCEDURE

No.
5 Cutting If nature of damage is cracks or
holes, cut a guide slit of 20 to 30
mm (0.79 to 1.18 in) in length along
the crack or hole up to the bumper’s
base surface. Then, bevel or “vee-
out” the affected area using a knife
or grinder.
G5M0165
6 Sanding (I) Grind beveled surface with sandpaper (#40 to #60) to smooth finish.
7 Cleaning Clean the sanded surface with the same solvent as used in Process No. 4.
8 Temporary welding Grind the side just opposite the beveled area with sandpaper (#40 to #60) and
clean using a solvent. Temporarily spot-weld the side, using a PP welding rod and
heater gun.
G5M0166
NOTE:
I Do not melt welding rod until it flows out. This results in reduced strength.
I Leave the welded spot unattended until it cools completely.
9 Welding Using a heater gun and PP welding rod, weld the beveled spot while melting the rod
and damaged area.
G5M0167
NOTE:
I Melt the sections indicated by hatched area.
I Do not melt welding rod until it flows out, in order to provide strength.
I Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
I Leave the welded spot unattended until it cools completely.
44
SERVICE PROCEDURE [W7C0] 5-1

No.
10 Sanding (II) Remove excess part of weld with a putty knife. If a drill or disc wheel is used
instead of the knife, operate it at a rate lower than 1,500 rpm and grind the excess
part little by little. A higher rpm will cause the PP substrate to melt from the heat.
G5M0168
Sand the welded spot smooth with #240 sand paper.
11 Masking Mask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
12 Cleaning/ degreasing Completely clean the entire coated area, using solvent similar to that used in Pro-
cess No. 4.
13 Primer coating Apply a coat of primer to the repaired surface and its surrounding areas. Mask
these areas, if necessary.
Recommended primer: Mp/ 364 PP Primer
NOTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa (2.5
to 3.5 kg/cm2, 36 to 50 psi) with a spray gun.
14 Leave unattended. Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer
is half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth damp-
ended with alcohol. (Do not use thinner since the coated area tends to melt.)
15 Primer surfacer coating Apply a coat of primer surfacer to the repaired area two or three times at an interval
of 3 to 5 minutes.
Recommended surfacer:
I UPS 300 Flex Primer
I No. 303 UPS 300 Exclusive hardener
I NPS 725 Exclusive Reducer (thinner)
I Mixing ratio: 2 : 1 (UPS 300: No. 303)
I Coated film thickness: 40 — 50µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at
60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sandpaper and
water.
18 Cleaning/ degreasing Same as Process No. 12.
19 Top coat (I) Solid color Metallic color
Use a “block” coating method. Use a “block” coating method.
I Recommended paint: I Recommended paint:
Suncryl (SC) Suncryl (SC)
No. 307 Flex Hardener No. 307 Flex Hardener
SC Reducer (thinner) SC Reducer (thinner)
I Mixing ratio: 3 : 1 I Mixing ratio: 3 : 1
(Suncryl: No. 307) (Suncryl: No. 307)
I Viscosity: 11 — 13 sec/20°C I Viscosity: 11 — 13 sec/20°C (68°F)
(68°F) I Coated film thickness: 20 — 30µ
I Coated film thickness: 40 — 50µ I Spraying thickness: 245 — 343 kPa
I Spraying thickness: 245 — 343 (2.5 — 3.5 kg/cm2, 36 — 50 psi)
kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
45

No.
20 Leave unattended. Not required. Leave unattended at 20°C (68°F) for at least
10 minutes until the topcoated area is half-dry.
NOTE:
Be careful to keep dust or dirt from coming in
contact with the affected area.
21 Top coat (II) Not required. Apply a clear coat three times at an interval of
3 to 5 minutes.
I Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
I Mixing ratio: 3 : 1
(SC710: No. 307)
I Coated film thickness: 20 — 30µ
I Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
22 Drying Allow the coated surface to dry at 20°C (68°F) for two hours or 60°C (140°F) for 30
minutes.
NOTE:
Do not allow the temperature to exceed 80°C (176°F) since this will deform the PP
substrate.
23 Inspection Carefully check the condition of the repaired area.
24 Masking removal Remove masking tape applied in Process No. 11 and 13.
25 Parts installation Install parts on bumper in reverse order of removal.
26 Bumper installation Install bumper.
46
8. Side Protector
8. Side Protector NOTE:

I Type A: Insert clip pins into holes in body, then
A: REMOVAL AND INSTALLATION fit end cap buffers into place.
I Type B: Insert spin weld clips into holes in body,
NOTE: then fit bushings into place.
Do not re-use protector. I Type C and D: Align the clips with holes in body
1) Type A and B: and insert them.
Protector is attached to body with clips. I Install clips in standard holes first.
While holding end of protector by hand, force pro-
tector out.
H5M0718A
G5M0170
2) Type C:
Protector is attached to body with clips.
Remove door inner trim, and detach protector by
pushing clip pawl from inside.
3) Type D:
Protector is attached to body with clips.
While holding end of protector by hand, force pro-
tector out.
G5M0171
47
9. Front Fender
9. Front Fender NOTE:

Check for alignment of front fender with hood and
A: REMOVAL AND INSTALLATION front door with front fender at all points. Adjust, if
necessary.
1) Disconnect ground cable from battery.
2) Remove mud guard.
3) Remove parking light and headlight.
4) Remove front bumper.
5) Remove bolts which secure fender to radiator
panel and turn signal light connector.
G5M0175
G5M0174
G5M0176
G5M0115
6) Remove body protector. (This step may be

skipped if fender is to be reused.)
7) Remove attaching bolt to remove fender.
CAUTION:
Be careful not to scratch body panels with
fender edges when removing it.
48
11. Cowl Panel
10. Mud Guard and Rear Arch 11. Cowl Panel

Protector A: REMOVAL AND INSTALLATION
A: REMOVAL AND INSTALLATION 1) Remove wiper arms.
2) Open front hood.
1. MUD GUARD
3) Pry clip off front hood seal using a screwdriver.
1) Jack-up vehicle to remove tire. 4) Lift cowl panel and remove clips from wind-
2) Remove screws and clips. Move mud guard shield.
toward the center of the body and remove mud
guard.
G5M0544
G5M0177
NOTE:
Install middle clip and other clips in that order.
CAUTION:
Only use new nuts and clips.
2. REAR ARCH PROTECTOR
1) Remove clip and screws.
G5M0545
G5M0178
2) Remove arch protectors.

CAUTION:
49
11. Cowl Panel
10. Mud Guard and Rear Arch 11. Cowl Panel

Protector A: REMOVAL AND INSTALLATION
A: REMOVAL AND INSTALLATION 1) Remove wiper arms.
2) Open front hood.
1. MUD GUARD
3) Pry clip off front hood seal using a screwdriver.
1) Jack-up vehicle to remove tire. 4) Lift cowl panel and remove clips from wind-
2) Remove screws and clips. Move mud guard shield.
toward the center of the body and remove mud
guard.
G5M0544
G5M0177
NOTE:
Install middle clip and other clips in that order.
CAUTION:
2. REAR ARCH PROTECTOR
1) Remove clip and screws.
G5M0545
G5M0178
2) Remove arch protectors.

CAUTION:
49
12. Molding and Retainer
12. Molding and Retainer 13. Front Grille

1) Remove weatherstrip. 1) Remove two upper clips from body panel. To
2) Remove tapping screws. facilitate removal, press portion shown in figure
using screwdriver while lightly pulling front grille.
G5M0181
H5M0719A
NOTE: 2) Installation is in the reverse order of removal.
Insert clips onto hooks, then fasten with screws. NOTE:
Attach all clips to grille. Align them with clip hole in
body and push them into place.
G5M0182
50
12. Molding and Retainer
12. Molding and Retainer 13. Front Grille

1) Remove weatherstrip. 1) Remove two upper clips from body panel. To
2) Remove tapping screws. facilitate removal, press portion shown in figure
using screwdriver while lightly pulling front grille.
G5M0181
H5M0719A
NOTE: 2) Installation is in the reverse order of removal.
Insert clips onto hooks, then fasten with screws. NOTE:
Attach all clips to grille. Align them with clip hole in
body and push them into place.
G5M0182
50
14. Sunroof
14. Sunroof 5) Close sunroof and remove nuts.
A: REMOVAL
1. SUNROOF PANEL
1) Open sunroof approx. 1/3.
2) Remove clips attached to front side of sunroof
trim by pulling trim from inside of compartment.
G5M0188
6) Remove sunroof panel.

NOTE:
Sunroof trim reference pin must be fitted in holder
notch.
G5M0185
2. SUNROOF MOTOR AND RELAY
3) Move trim forward, and detach trim end from 1) Remove roof trim, rear quarter trim, pillar trim,
holder. etc.
<Ref. to 5-3 [W500].>
2) Remove screw.
3) Disconnect connector.
G5M0186
4) Detach trim.
G5M0190
4) Remove relay by pulling it out.

3. SUNROOF FRAME
1) Remove roof trim, rear quarter trim, pillar trim,
etc.
<Ref. to 5-3 [W500].>
2) Remove sunroof panel.
3) Disconnect front and rear drain tubes.
G5M0187
G5M0193
51
5-1 [W14B0] SERVICE PROCEDURE
14. Sunroof
4) Disconnect connector between body harness B: INSTALLATION

and sunroof harness.
1) Insert frame rear end slit to two bolts fitted tem-
porarily to roof brace.
G5M0194
5) Loosen two mounting bolts near motor. (Do not G5M0198

remove bolts.)
2) Align frame to reference pin install
ed on roof.
G5M0195
6) Remove six bolts, and four adjusting nuts. G5M0199
3) Tighten adjusting nut (that is, set frame at high-

est position).
Temporarily tighten bolts.
G5M0196
7) Remove sunroof frame.

8) Loosen set bracket mounting bolt.
G5M0200
4) Install sunroof panel.
G5M0197
52
SERVICE PROCEDURE [W14B0] 5-1
14. Sunroof
5) Adjust height by turning adjusting nut. 8) Install drain tubes.

Also adjust front, rear, right, and left side partitions. CAUTION:
Partition clearance: Insert drain tube securely into drain pipe.
5.9±0.5 mm (0.232±0.020 in) Length: A
Approx. 20 mm (0.79 in)
G5M0201
G5M0205
Difference in height between roof panel and
sunroof panel: 9) Install roof trim.
0±1.0 mm (0±0.039 in) 10) Install garnish.
NOTE:
Place garnish joint at rear center of body.
G5M0202
6) Tighten set bracket mounting bolts.

G5M0206
11) Install sunroof trim, pillar trim, rear quarter trim

etc.
12) Check the following items after assembling all
parts;
(1) Garnish must be free from waves.
(2) When sunroof is fully closed, must be no
clearance between garnish and sunroof trim.
(3) Sunroof must be free from slack and noise
when it is fully opened and closed.
G5M0203
7) Tighten bolts.
G5M0204
53
15. Rear Spoiler
15. Rear Spoiler 16. Hood Duct

1. COUPE 1. CENTER DUCT
1) Remove stoppers from both sides of trunk lid. 1) Open the hood.
2) Remove clip and screws, then remove brace
cover.
G5M0616
2) Disconnect high-mount stop light connector.

H5M0930
3) Remove six nuts.

4) Disconnect the two clips from hood, then
remove hood duct grille.
G5M0617
3) Remove nuts from rear spoiler.

CAUTION:
Be careful not to drop nuts into box section of
H5M0747A
trunk lid.
2. SIDE DUCT
1) Open the hood.
2) Remove four nuts.
3) Disconnect the two clips from brace cover, then
remove brace cover.
H5M0673A
4) Lift rear spoiler and unfasten clips.

5) Remove spoiler from trunk lid.
CAUTION:
Be careful not to damage trunk lid.
Tightening torque: H5M0748A
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
4) Remove duct grille.
54
15. Rear Spoiler
15. Rear Spoiler 16. Hood Duct

1. COUPE 1. CENTER DUCT
1) Remove stoppers from both sides of trunk lid. 1) Open the hood.
2) Remove clip and screws, then remove brace
cover.
G5M0616
2) Disconnect high-mount stop light connector.

H5M0930
3) Remove six nuts.

4) Disconnect the two clips from hood, then
remove hood duct grille.
G5M0617
3) Remove nuts from rear spoiler.

CAUTION:
Be careful not to drop nuts into box section of
H5M0747A
trunk lid.
2. SIDE DUCT
1) Open the hood.
2) Remove four nuts.
3) Disconnect the two clips from brace cover, then
remove brace cover.
H5M0673A
4) Lift rear spoiler and unfasten clips.

5) Remove spoiler from trunk lid.
CAUTION:
Be careful not to damage trunk lid.
Tightening torque: H5M0748A
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
4) Remove duct grille.
54
DIAGNOSTICS [K100] 5-1
1. Sunroof
1. Sunroof
Entry of water into compartment (1) Check roof panel and sunroof panel for improper or poor sealing.
(2) Check drain tube for clogging.
(3) Check sunroof frame seal and body for improper fit.
Booming noise (1) Check roof panel and roof panel for improper clearance.
(2) Check sunroof trim and roof trim for improper clearance.
Abnormal motor noise (1) Check motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cable for wear.
(4) Check cable pipe for deformities.
Failure of sunroof to operate (Motor operates properly.) (1) Check guide rail for foreign particles.
(2) Check guide rail for improper installation.
(3) Check parts for mutual interference.
(4) Check cable slider for improper clinching.
(5) Check cable for improper installation.
(6) Check clutch adjustment nut for improper tightness.
Motor does not rotate or rotates improperly. (Use sun- (1) Check fuse for blowout.
roof wrench to check operation.) (2) Check switch for improper function.
(3) Check motor for incorrect terminal voltage.
(4) Check relay for improper operation.
(5) Check poor grounding system.
(6) Check cords for discontinuity and terminals for poor connections.
(7) Check limit switch for improper operation.
55
5-1 DIAGNOSTICS
MEMO:
56
1. Door Alignment
1. Door Alignment
A: SEDAN AND WAGON MODEL
G5M0485
2
1. Door Alignment
B: COUPE MODEL
G5M0637
3
1. Front Door
1. Front Door
H5M0903A
(1) Gusset (8) Checker Tightening torque: N·m (kg-m, ft-lb)

(2) Weatherstrip (9) Guide
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Stabilizer (Outer) (10) Sealing cover
T2: 13±3 (1.3±0.3, 9.4±2.2)
(4) Stabilizer (Inner) (11) Door panel
T3: 25±3 (2.5±0.3, 18.1±2.2)
(5) Protector (12) Lower hinge
(6) Stopper (13) Upper hinge T4: 29±5 (3.0±0.5, 21.7±3.6)
(7) Knock pin
4
2. Rear Door
2. Rear Door
H5M0904A
(1) Weatherstrip (7) Seating cover Tightening torque: N·m (kg-m, ft-lb)
(2) Stabilizer (Outer) (8) Door panel
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Stabilizer (Inner) (9) Lower hinge
T2: 25±3 (2.5±0.3, 18.1±2.2)
(4) Stopper (10) Upper hinge
T3: 29±5 (3.0±0.5, 21.7±3.6)
(5) Knock pin
(6) Checker
5
3. Fixed Glass
3. Fixed Glass
H5M0698C
(1) Windshield glass (4) Molding (7) Rear quarter glass (Coupe)
(2) Dam rubber (5) Rear window glass (8) Fastener
(3) Locate pin (6) Rear quarter glass (Wagon)
6
4. Front Door Glass
4. Front Door Glass
H5M0905A
(1) Door sash (Front) (6) Regulator handle Tightening torque: N·m (kg-m, ft-lb)
(2) Glass (Except power window)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Door sash (Rear) (7) Retainer spring
T2: 14±4 (1.4±0.4, 10.1±2.9)
(4) Weatherstrip (Inner) (8) Regulator ASSY
(5) Regulator and motor ASSY
7
5. Rear Door Glass
5. Rear Door Glass
H5M0906A
(1) Door sash (Front) (6) Regulator handle Tightening torque: N·m (kg-m, ft-lb)
(2) Glass (Except power window)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Weatherstrip (Inner) (7) Retainer spring
T2: 14±4 (1.4±0.4, 10.1±2.9)
(4) Door sash (Rear) (8) Regulator ASSY
(5) Regulator and motor ASSY
8
6. Rear Gate and Glass
6. Rear Gate and Glass
H5M0907A
(1) Rear gate (8) Glass pin (15) Hinge

(2) Clip (9) Trim
(3) Key cylinder (10) Glass Tightening torque: N·m (kg-m, ft-lb)
(4) Outer handle (11) Buffer T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(5) Auto-door lock actuator (12) Rear gate side buffer T2: 14±4 (1.4±0.4, 10.1±2.9)
(6) Striker (13) Stud T3: 25±5 (2.5±0.5, 18.1±3.6)
(7) Latch (14) Gas stay
9
5-2 [C7A0] COMPONENT PARTS
7. Door Lock Assembly

A: FRONT DOOR
H5M0908A
(1) Cover (6) Switch ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Inner remote ASSY (7) Auto-door lock actuator
T1: 6.4±2.0 (0.65±0.2, 4.7±1.4)
(3) Door outer handle
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(4) Striker
T3: 14±4 (1.4±0.4, 10.1±2.9)
(5) Door latch
10
COMPONENT PARTS [C7B0] 5-2
B: REAR DOOR
H5M0909A
(1) Door outer handle (6) Cover Tightening torque: N·m (kg-m, ft-lb)
(2) Door latch (7) Inner remote ASSY
T1: 6.4±2.0 (0.65±0.2, 4.7±1.4)
(3) Auto-door lock actuator
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(4) Striker
T3: 14±4 (1.4±0.4, 10.1±2.9)
(5) Rod holder
11
8. Door Trim
8. Door Trim
H5M0928A
(1) Trim panel (Coupe) (4) Gusset cover (7) Weatherstrip

(2) Trim panel (Except coupe/front) (5) Bracket
(3) Trim panel (Except coupe/rear) (6) Cover
12
9. Weatherstrip
9. Weatherstrip
H5M0700B
(1) Rear gate weatherstrip (3) Upper and side weatherstrip (6) Weatherstrip (Front door)
(Wagon only) (4) Retainer (Center)
(2) Retainer and molding (5) Weatherstrip (Rear door)
13
5-2 [W100] SERVICE PROCEDURE
1. Procedure Chart for Removing and Installing Door and Related Parts
1. Procedure Chart for Removing and Installing Door and Related

Parts
NOTE:
This flowchart shows the main procedures for removing and installing the door and its related parts. For
details, refer to the text.
H5M0910A
14
2. Door
2. Door 2. TRIM PANEL

1) Press retainer spring (A) with a thin flat-bladed
A: REMOVAL AND INSTALLATION screwdriver and then remove regulator handle (B).
1. DOOR ASSEMBLY (models without power window)
1) Remove lower trim and disconnect connectors
from body harness.
2) Place a cloth or a wood block under door to
prevent damage, and support it with a jack.
3) Remove checker pin by driving it upward. Be
careful not to damage door and body.
B5M0329C
2) Using ST, disengage the clip.

ST 925580000 PULLER
G5M0486
4) Remove bolts (M8) securing upper and lower

hinges to door, and remove door from hinges.
Tightening torque:
25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
5) Remove hinges by loosening hinges mounting
bolt (M8) off of body. G5M0390
Tightening torque:
29±5 N·m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
CAUTION:
Work carefully to avoid damaging door.
G5M0385

NOTE:
Apply grease to moving parts of door hinges.
15
2. Door
3) Remove gusset cover (C) and screws. I When repairing or replacing sealing cover, use
4) Remove trim panel and then disconnect con- “CEMEDINE 5430L” as sealer. It may be overlaid
nector. (models with power window) on existing sealer.
CAUTION: Sealer:
Be careful not to break clip by applying undue CEMEDINE 5430L
force. CAUTION:
I Any breaks in sealer can cause water leak-
age or entry of air and dust. Be sure sealer is
applied in a continuous line.
I Make sure sealing cover bonded areas are
free from wrinkles or openings.
4. CHECKER
1) Remove trim panel.
2) Remove sealing cover.
3) Apply a cloth to door and body to prevent dam-
aging them, and remove checker pin by driving it
upward.
CAUTION:
Be careful not to damage door and body.
H5M0929A

3. SEALING COVER G5M0392
1) Remove trim panel. 4) Completely close door glass.

2) Remove speaker, trim bracket and remote 5) Loosen two nuts securing checker, and take out
assembly and disconnect connectors. checker through access hole in underside.
3) Remove sealer with a spatula. 6) Installation should be made in the reverse order
of removal.
CAUTION:
Be careful because cover may break if sealer is Tightening torque:
removed forcefully. 7.5±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
5. INNER REMOTE
3) Disconnect joints of two rods.
G5M0391

NOTE:
I Confirm that sealer is properly applied without G5M0394
breaks. Then install sealing cover.
16
2. Door
4) Unlatch rod holder. 6) Loosen screws securing both latch and

5) Remove screws holding remote assembly. actuator, then remove latch and actuator assembly
through service hole in bottom.
G5M0395
G5M0396
NOTE:
If rear door is equipped with child safety lock, Tightening torque (screw):
check that child lock lever moves without dragging. 6.4±2.0 N·m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
6. DOOR LATCH NOTE:
I Check operation of each part.
1) Remove trim panel. I Check each sliding part for proper lubrication.
2) Remove inner remote assembly.
CAUTION:
3) Remove sealing cover around latch service
After installation, be sure lock mechanism
hole.
operates normally.
4) Completely close door glass.
5) Remove latch and actuator assembly: 7. OUTER HANDLE
(1) Turn rod holder to disconnect joint between 1) Remove trim panel.
key lock and rod. 2) Remove sealing cover.
(2) Turn rod holder to disconnect joint between 3) Detach door latch rod from outer handle and
outer handle and rod. key lock.
(3) Turn rod holder to disconnect joint between 4) Loosen nut securing outer handle and then
crank and rod. remove outer handle from outside.
CAUTION:
Be careful not to damage door.
G5M0397
G5M0398

Tightening torque:
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
8. KEY LOCK
3) Completely close door glass.
4) Remove outer handle.
5) Loosen spring securing key lock.
17
2. Door
6) Remove key lock from outer handle. 2) Loosen screw one complete rotation, and
7) Installation is in the reverse order of removal. adjust opening/closing direction of door using a
NOTE: hammer covered with a cloth.
Install so that key slot in key lock comes to center CAUTION:
of hole in outer handle. Be careful not to damage striker.
9. GUSSET Hinge tightening torque (body side):
1) Be sure window is all the way down. 29±5 N·m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
2) Remove gusset cover. Striker tightening torque:
3) Remove trim panel. 14±4 N·m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
4) Remove door rearview mirror.
5) Remove outer weatherstrip. 2. INNER REMOTE
6) Remove sealing cover. 1) Lock the door.
NOTE: 2) Loosen bolt (A).
Be careful not to drop nuts on the “IN” side. 3) Lower bell crank (B) and then tighten bolt (A).
7) Remove bolts and nuts which secure gusset.
Tightening torque: Bolt
3±3 N·m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
Tightening torque: Nut
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
H5M0911A
G5M0399
8) Lift out gusset.

B: ADJUSTMENT
1. DOOR ASSEMBLY
1) Using ST, loosen bolts securing upper and
lower hinges to body, and adjust fore-and-aft and
vertical alignment of door.
ST 925610000 DOOR HINGE WRENCH
G5M0487
18
2. Door
3. PROCEDURE CHART FOR ADJUSTING DOOR GLASS
H5M0912A
19
2. Door
4. FRONT DOOR GLASS
H5M0697B
20
2. Door
H5M0728B
I Door glass fit adjustment

Before adjusting door glass alignment, ensure
adjusting bolts for stabilizers, upper stoppers and
sashes are loose and glass is raised so that it is in
contact with upper and side weatherstrip.
1) emporarily tighten one of the two rear sash
adjusting bolts, at midpoint of oblong hole on inner
panel.
2) Temporarily tighten regulator B channel at a
position slightly lower than midpoint of oblong hole
on inner panel.
21
2. Door
3) Lower door glass 10 to 15 mm (0.39 to 0.59 in) 3) If glass tilts to far rearward, loosen adjusting nut
from fully closed position. While applying outward (0C) and adjust glass to be parallel with center
pressure (load) to upper edge of glass above mid- pillar, then after adjustment, tighten adjusting nut
point of two outer stabilizers, press inner stabilizer (0C).
until it just touches the glass, then secure it. Tightening torque:
Load: F 7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
Front door glass 44.1±4.9 N (4.5±0.5 kg,
9.9±1.1 lb)
Rear door glass 44.1±4.9 N (4.5±0.5 kg,
9.9±1.1 lb)
H5M0687A
G5M0421
I Remedy for unequal dimensions,

between upper, lower and center pillar
sides
1) Close front door and raise door glass.
2) Make sure of unequal dimensions.
H5M0689A
I Remedy for improper glass to center

pillar clearance
G5M0639
22
2. Door
2) Make sure of improper clearance. 2) Increase the upward travel of window glass up
to the position where upper edge just touches
weatherstrip surface with door closed.
H5M0688A
G5M0511
3) After adjustment, temporarily tighten stoppers.

NOTE:
Make sure that each glass stopper is touched.
I Remedy for incorrect contact of door
glass to weatherstrip
2) If clearance is below specifications, loosen bolt
H5M0690A
(A) and bolt (B).
3) If clearance is improper, loosen adjusting nut 3) If clearance is over specifications, tighten bolt
(A), bolt (A) and adjust glass to center pillar. (A) and bolt (B).
H5M0692B H5M0693A
I Fit adjustment
Door glass fit is adjusted by displacing the glass
front edge with a stabilizer.
NOTE:
Before adjusting glass fit, visually check to deter-
mine relative adjusting positions of retainer and
molding (on roof side) and glass surface.
H5M0691A
I Remedy for improper upper stop point

of door glass
1) Loosen front and rear sash stoppers.
23
2. Door
1) Alternately adjust two rear sash adjusting bolts 2) Adjust front sash fit using rear sash adjustment
(0A) until dimensions are obtained. procedure outlined in the former procedure as a
CAUTION: guide. Two adjusting bolts must be adjusted by the
Do not loosen two adjusting nuts (A) at the same amount.
same time, as this moves sash fore and aft, NOTE:
creating unequal glass- to-sash clearance. Dur- I Front and rear sash adjustment procedures are
ing adjustment, loosen only one nut and keep basically the same; however, the amount of adjust-
the other tightened. ment is not always the same due to alignment dis-
persion of individual doors.
I Adjust front and rear sash fit, as equally as pos-
sible. Otherwise, effort required to operate regula-
tor may increase.
3) After adjusting front sash-to-glass fit, secure
front sash.
H5M0693A
NOTE:
Always adjust two rear sash adjusting bolts (0A) by
the same amount. Do not adjust the adjusting bolts
with sash bracket inclined toward inner panel, as
this increases effort required to operate regulator.
G5M0510
24
2. Door
5. REAR DOOR GLASS

Alignment of rear door glass is basically the same as for the front door glass. Due to slight difference in
adjustment dimensions for fore-aft, up-down, and in-out alignments, key points for rear door adjustment are
described.
H5M0913A
25
2. Door
I Fore-aft adjustment I Fit adjustment

1) Door glass alignment must be adjusted so that Increasing contact pressure causes rear door
glass- to-center pillar fit is equal at all points. glass to be caught in center pillar upper and lower
Always use dimensions as a guide during adjust- weatherstrip; this will cause premature weather-
ment. strip wear. For this reason, always use dimensions
NOTE: indicated in figure as a guide during glass fit adjust-
If dimensions are smaller than those indicated, ment.
glass will be caught in weatherstrip and may not
raise to the fully closed position.
H5M0693A
G5M0472
2) After making fore-aft adjustment, raise and

lower glass to ensure it is free from any binding.
C: INSPECTION
1. FRONT DOOR GLASS
1) Close front door and make sure of all clearances.
H5M0695A
H5M0696A
2) If any clearance is not correct, adjust affected I After clearance adjustment, make sure that
parts. Re-check that all clearances are correct. all adjusting bolts and nuts are tightened.
CAUTION:
I Repeatedly adjust parts until all clearances
are correct.
26
3. Rear Gate
2. REAR DOOR GLASS

1) Close rear door and make sure of all clearances.
G5M0474
2) If any clearance is not correct, adjust affected 3. Rear Gate

parts. Re-check that all clearances are correct.
CAUTION: A: REMOVAL AND INSTALLATION
I Repeatedly adjust parts until all clearances CAUTION:
are correct. I Be careful not to scratch coated surfaces of
I After clearance adjustment, make sure that vehicle body and window glass during
all adjusting bolts and nuts are tightened. removal. Place a cloth over the affected area.
I Be careful not to damage trim panels.
I Use an assistant when handling heavy parts.
I Be careful not to damage or lose small parts.
1. REAR GATE ASSEMBLY
1) Remove clips from trim panel and detach trim
panel.
CAUTION:
Be careful not to damage clips or their holes.
G5M0400
2) Disconnect connectors and terminal.

3) Disconnect rear washer hose from wiper motor.
4) Remove high-mounted stop light.
27
3. Rear Gate
2. REAR DOOR GLASS

1) Close rear door and make sure of all clearances.
G5M0474
2) If any clearance is not correct, adjust affected 3. Rear Gate

parts. Re-check that all clearances are correct.
I Repeatedly adjust parts until all clearances CAUTION:
are correct. I Be careful not to scratch coated surfaces of
I After clearance adjustment, make sure that vehicle body and window glass during
all adjusting bolts and nuts are tightened. removal. Place a cloth over the affected area.
I Be careful not to damage trim panels.
I Use an assistant when handling heavy parts.
I Be careful not to damage or lose small parts.
1. REAR GATE ASSEMBLY
1) Remove clips from trim panel and detach trim
panel.
CAUTION:
Be careful not to damage clips or their holes.
G5M0400
2) Disconnect connectors and terminal.

3) Disconnect rear washer hose from wiper motor.
4) Remove high-mounted stop light.
27
3. Rear Gate
5) If disconnected harness is re-used, tie connec- 9) Remove the bolts which hold rear gate to hinge
tor with a string and place on the upper side of rear and then detach rear gate.
gate for ready use.
CAUTION:
o not forcefully pull cords, lead wires, etc.
since damage may result; carefully extract
them in a wavy motion while holding connec-
tors.
G5M0403
10) General precautions in handling rear gate gas

stay
CAUTION:
I Do not attempt to disassemble gas stay
G5M0401
because its cylinder is filled with gas.
I Before discarding gas stay, place it at a
6) Remove rear wiper. <Ref. to 6-2 [W6B0].> slight angle with the cylinder body side facing
7) Remove both rubber ducts and then extract up and drill a 2 to 3 mm (0.08 to 0.12 in) dia.
washer hose and harness connector. hole to completely discharge the content. (Gas
8) Gas stay: is odorless, colorless and harmless; however,
(1) Completely open rear gate. metal powder may come out of the hole.)
(2) Remove bolts which hold gas stay to rear
gate.
CAUTION:
I Be careful because rear gate drops while
removing bolts. Have an assistant support it
while removing bolts.
I Be sure to place a folded cloth between rear
gate and body to prevent scratches.
G5M0490
I It is good practice to place a vinyl sack over

it before drilling the hole because oil may spurt
out. Be careful to prevent vinyl cover from
becoming entangled on the drill.
G5M0402
G5M0491
I Be careful not to scratch the exposed sec-

tion of piston rod or allow oil or paint to come
in contact with it.
28
3. Rear Gate
I Do not attempt to rotate the extended piston CAUTION:

rod. Completely insert latch pin into handle lever.
11) Installation is in the reverse order of removal. 4. KEY CYLINDER
CAUTION: 1) Remove trim panel.
I Be careful not to mistake RH and LH body 2) Disengage rod from holder.
side buffers. 3) Remove retaining spring from key cylinder, and
I Be sure to add sealer to hinge. detach key cylinder from outside.
I When installing rear gate, be careful not to 4) Installation is in the reverse order of removal.
damage coating on body and rear gate.
5. STRIKER
2. LATCH
1) Remove rear skirt trim.
1) Remove trim panel. 2) Remove two bolts from striker and detach
2) Disengage rod from holder (= key cylinder). striker.
3) Remove bolts from auto-door lock actuator.
4) Remove bolts from latch, and detach latch.
G5M0406
G5M0404 3) Installation is in the reverse order of removal.

5) Disconnect rear gate switch connector. 6. WEATHERSTRIP
6) Disconnect auto-door lock actuator connector.
7) Detach latch. 1) Place weatherstrip so that its joints meet at
8) Installation is in the reverse order of removal. lower center of vehicle body, and install by insert-
ing flanged portion from below, as shown in section
CAUTION: A—A in figure.
Firmly join latch with key cylinder, and outer
handle.
3. OUTER HANDLE
2) Remove latch.
3) Remove two nuts used to hold outer handle to
the inside of rear gate, and detach outer handle.
CAUTION:
Be careful not to damage packing when remov-
ing outer handle.
G5M0492
G5M0405
29
3. Rear Gate
2) Tap along entire length with a rubber hammer to

firmly insert body flange into weatherstrip.
CAUTION:
I Be careful not to install in wrong direction.
I Install weatherstrip carefully and firmly.
G5M0493
30
4. Procedure Chart for Removal and Installing Window Glass
4. Procedure Chart for Removal and Installing Window Glass

H5M0914A
31
5. Windshield
1. MATERIALS REQUIRED FOR 5. Windshield

APPLICATION
A: REMOVAL
Description Remarks
Repair adhesive set Sunstar No. 580 or Essex 1. USING WINDSHIELD KNIFE
I Cartridge of single-liquid Chemical Corp’s Urethane E The following procedure for the front windshield
urethane adhesive Sunstar No. 435-580 can also be applied to other window glass.
I Primer for glass and body
1) Remove wiper arm and cowl panel.
Windshield knife or piano For cutting windshield
2) Remove roof molding and front window molding
wire
upper.
Sealant gun For applying adhesive
3) Remove glass:
Suction cups For holding glass
(1) Put protective tape on body to prevent dam-
Putty knife For finishing adhesion sur-
age.
face and cutting spacer
(2) Apply soapy water to the surface of the
Sponge For applying primer
adhesive agent so the knife blade slides
Gauze or cloth For cleaning
smoothly.
Alcohol or white gasoline For cleaning adhesion sur-
(3) Cut off excess adhesive agent.
face
(4) Put windshield knife into layer of adhesive.
Tape For preventing damage to
painted surface
(5) Cut adhesive layer with the windshield
knife.
CAUTION:
I Keep knife edge along glass surface and end
face.
I When first putting knife into layer of
adhesive, select point with wide gap between
body and glass.
G5M0418
32
5. Windshield
1. MATERIALS REQUIRED FOR 5. Windshield

APPLICATION
A: REMOVAL
Description Remarks
Repair adhesive set Sunstar No. 580 or Essex 1. USING WINDSHIELD KNIFE
I Cartridge of single-liquid Chemical Corp’s Urethane E The following procedure for the front windshield
urethane adhesive Sunstar No. 435-580 can also be applied to other window glass.
I Primer for glass and body
Windshield knife or piano For cutting windshield
2) Remove roof molding and front window molding
wire
upper.
Sealant gun For applying adhesive
3) Remove glass:
Suction cups For holding glass
(1) Put protective tape on body to prevent dam-
Putty knife For finishing adhesion sur-
age.
face and cutting spacer
(2) Apply soapy water to the surface of the
Sponge For applying primer
adhesive agent so the knife blade slides
Gauze or cloth For cleaning
smoothly.
Alcohol or white gasoline For cleaning adhesion sur-
(3) Cut off excess adhesive agent.
face
(4) Put windshield knife into layer of adhesive.
Tape For preventing damage to
painted surface
(5) Cut adhesive layer with the windshield
knife.
CAUTION:
I Keep knife edge along glass surface and end
face.
I When first putting knife into layer of
adhesive, select point with wide gap between
body and glass.
G5M0418
32
5. Windshield
NOTE: 2) Finishing adhesion surface on body side: Using

A matching pin is cemented to corners of glass on a cutter knife etc., cut layer of adhesive sticking
compartment side. Use a piano wire when cutting firmly to body, and finish it to a smooth surface of
each pin. about 2 mm (0.08 in) in thickness.
CAUTION:
Take extra care not to cause damage to body
paint.
G5M0412
2. USING PIANO WIRE

G5M0553
2) Remove roof molding and front window molding 3) Cleaning body surface:
upper. (1) Thoroughly remove chips, dirt and dust
3) Remove glass: from body surface.
(1) Put protective tape on body to prevent dam- (2) Clean body wall surface and upper surface
age. of layer of adhesive with a solvent such as alco-
(2) Using drill or putty knife, make through-hole hol or white gasoline.
(one place) in adhesive agent. 4) Positioning glass:
(3) Pass piano wire through the hole from (1) Mount glass on body.
inside the compartment, and connect both ends (2) Adjust position of glass so that gap between
of wire securely to wooden blocks. body and glass is uniform on all sides.
(3) Put matching pin on body and glass in sev-
eral places.
G5M0494
(4) Cut adhesive layer with the wire by pulling

G5M0407
it back and forth.
CAUTION: 5) Cleaning glass:
When making through-hole into adhesive layer (1) Dismount glass from body.
and cutting the adhesive, be careful not to (2) Clean surface of glass to be adhered with
damage interior and exterior parts. alcohol or white gasoline.
B: INSTALLATION
1) After cutting layer of adhesive, remove gum
rubber remaining on body.
33
5. Windshield
6) Application of primer: (2) Mount glass on body with matching pin

(1) Using a sponge, apply primer to part of aligned.
glass to be adhered.
(2) Apply primer to part of body to be adhered.
CAUTION:
I Primer is hard to wipe off of body paint,
instrument panel, inner trim, etc. So put mask-
ing around these areas for protection.
I After application, let 1st primer dry sponta-
neously for about 10 minutes.
I Do not touch primer-coated surface under
any circumstances.
G5M0409
(3) Stick them fast by pressing all sides lightly.

9) Installation of molding:
(1) Remove adhesive overflowing from outside
of glass until it becomes level with outer height
of glass. Then, add adhesive to portions that
need it, and clean with alcohol or white gaso-
line.
G5M0495
7) Application of adhesive:
(1) Cut nozzle tip of cartridge as shown in fig-
ure.
G5M0496
(2) Firstly, press-fit front window molding upper

and lastly, roof molding.
CAUTION:
Do not open and close door after moldings
G5M0408
have been installed. When opening and closing
door for unavoidable reason, lower door glass
(2) Open cartridge and put it into a gun with and gently move door.
nozzle attached.
(3) Apply adhesive uniformly to all sides of
adhesion surface while operating gun along
glass end face.
8) Installation of glass:
(1) Hold glass with rubber suction cups.
G5M0417
10) Water leakage test:

Test for water leakage about one hour after instal-
lation.
34
6. Rear Window Glass
CAUTION: 6. Rear Window Glass

I Move vehicle very gently.
I Do not squirt strong hose stream on vehicle. A: REMOVAL
11) Spontaneous drying: 1. SEDAN AND COUPE MODEL
After completing all operations, leave vehicle alone
for 24 hours. 1) Remove roof molding.
2) Remove rear window molding upper and lower.
CAUTION: 3) Disconnect connector from rear defogger termi-
When delivering vehicle to user, tell him that nal.
vehicle should not be subjected to heavy 4) Remove glass in same manner as in wind-
shocks for at least three days.
shield.
12) Install cowl panel and wiper arm.
G5M0410
NOTE:
A matching pin is cemented to the corners of glass
on compartment side. Use a piano wire when cut-
ting each pin.
G5M0412
2. WAGON MODEL
NOTE:
It is impossible to remove the molding from the
glass. If molding is broken, replace rear glass.
1) Remove rear wiper and rear gate trim.
2) Disconnect connector from rear defogger termi-
nal.
3) Remove high mount stop light.
4) Remove glass in same manner as for wind-
shield.
CAUTION:
Be careful not to damage molding re-installing
the old rear window glass using a piano wire.
35
CAUTION: 6. Rear Window Glass

I Move vehicle very gently.
I Do not squirt strong hose stream on vehicle. A: REMOVAL
11) Spontaneous drying: 1. SEDAN AND COUPE MODEL
for 24 hours. 1) Remove roof molding.
2) Remove rear window molding upper and lower.
CAUTION: 3) Disconnect connector from rear defogger termi-
When delivering vehicle to user, tell him that nal.
vehicle should not be subjected to heavy 4) Remove glass in same manner as in wind-
shield.
12) Install cowl panel and wiper arm.
G5M0410
NOTE:
A matching pin is cemented to the corners of glass
on compartment side. Use a piano wire when cut-
ting each pin.
G5M0412
2. WAGON MODEL
NOTE:
It is impossible to remove the molding from the
glass. If molding is broken, replace rear glass.
1) Remove rear wiper and rear gate trim.
2) Disconnect connector from rear defogger termi-
nal.
3) Remove high mount stop light.
4) Remove glass in same manner as for wind-
shield.
CAUTION:
Be careful not to damage molding re-installing
the old rear window glass using a piano wire.
35
NOTE: 3) After installation, test for water leakage after

A matching pin is cemented to corners of glass on about one hour, and leave vehicle alone for 24
compartment side. Use a piano wire when cutting hours.
each pin. 4) Make rear defogger connections.
G5M0412
B: INSTALLATION
1. SEDAN AND COUPE MODEL
1) Install glass in same manner as in windshield.
2) Firstly, press-fit molding upper, then lower and
lastly, roof molding.
G5M0411
36
2. WAGON MODEL
1) Install rear gate trim.
2) Install glass in same manner as windshield.
G5M0413
3) About one hour after installation, test for water 5) Install high mount stop light and rear wiper.
leakage. Leave vehicle for 24 hours before using
it.
4) Connect rear defogger connections.
37
7. Rear Quarter Glass

A: REMOVAL
1. WAGON MODEL
1) Remove rear quarter molding on corner.
2) Remove glass in same manner as in windshield.
G5M0416
2. COUPE MODEL
1) Remove rear quarter molding.
G5M0627
2) Remove glass in same manner as in windshield.
G5M0628
38
B: INSTALLATION 5) Application of adhesive:

(1) Cut nozzle tip as shown in figure.
1. WAGON MODEL
1) Finish surface of adhesive layer on body: Using
a putty knife, etc., cut layer of adhesive stick firmly
to body and finish it into a smooth surface of about
2 mm (0.08 in) in thickness.
CAUTION:
Be careful not to damage body finish.
G5M0414
(2) Open cartridge and put it into a gun with

nozzle attached.
glass end face.
6) Installation of glass:
G5M0497 (1) Hold glass with rubber suction cups.
(2) Mount glass on body with matching pin
2) Cleaning of body surface:
aligned.
(1) Remove chips, dirt and dust from body sur-
face.
(2) Clean body wall surface and upper surface
of adhesive layer with a solvent such as alcohol
or white gasoline.
3) Cleaning glass:
(1) Remove dirt and dust from surface of glass
to be adhered.
(2) Clean surface of glass to be adhered with
alcohol or white gasoline.
4) Application of primer:
G5M0415
(1) Using a sponge, apply primer to surface of
glass to be adhered. (3) Stick them fast by pressing all sides lightly.
(2) Apply primer to surface of body to be 7) Water leakage test:
adhered. After installing glass, test for water leakage after
CAUTION: about one hour.
I If primer has dropped on body finish, it is CAUTION:
hard to wipe it off. So protect with masking. I Move vehicle slowly.
I Primer must not project from black frame of I When opening and closing door, lower door
glass. glass and move door gently.
I After applying primer, let it dry spontane-
I Do not squirt strong hose stream on vehicle.
ously for about 10 minutes.
8) Spontaneous drying:
for 24 hours.
CAUTION:
When delivering vehicle to user, tell him or her
that vehicle should not be subjected to heavy
G5M0495
39
2. COUPE MODEL 5) Application of adhesive:

1) Finish surface of adhesive layer on body: Using (1) Cut nozzle tip as shown in figure.
a putty knife, etc., cut layer of adhesive stick firmly
to body and finish it into a smooth surface of about
2 mm (0.08 in) in thickness.
CAUTION:
Be careful not to damage body finish.
G5M0629
(2) Open cartridge and put it into a gun with

nozzle attached.
G5M0497 glass end face.
2) Cleaning of body surface: 6) Installation of glass:
(1) Remove chips, dirt and dust from body sur- (1) Hold glass with rubber suction cups.
face. (2) Mount glass on body with matching pin
(2) Clean body wall surface and upper surface aligned.
of adhesive layer with a solvent such as alcohol
or white gasoline.
3) Cleaning glass:
(1) Remove dirt and dust from surface of glass
to be adhered.
(2) Clean surface of glass to be adhered with
alcohol or white gasoline.
4) Application of primer:
(1) Using a sponge, apply primer to surface of
glass to be adhered.
(2) Apply primer to surface of body to be G5M0630
adhered.
(3) Stick them fast by pressing all sides lightly.
CAUTION:
7) Water leakage test:
I If primer has dropped on b 5) ody finish, it is
hard to wipe it off. So protect with masking. After installing glass, test for water leakage after
I Primer must not project from black frame of about one hour.
glass. CAUTION:
I After applying primer, let it dry spontane- I Move vehicle slowly.
ously for about 10 minutes. I When opening and closing door, lower door
glass and move door gently.
I Do not squirt strong hose stream on vehicle.
8) Spontaneous drying:
for 24 hours.
CAUTION:
When delivering vehicle to user, tell him or her
that vehicle should not be subjected to heavy
G5M0495
40
1. Door Glass
1. Door Glass
Condition Apparent cause/Correction
Glass in fully 1) Glass runs out of weatherstrip lip when considerable hand I Insufficient upward travel of glass
closed position pressure is applied to it from inside. Increase upward travel of glass.
G5M0502
(This condition may cause wind/booming noise during
high- speed operation.)
2) Clearance exists between glass and weatherstrip when light I Insufficient glass-to-door weatherstrip
hand pressure is applied to it at center and rear pillar locations. contact
Check stabilizer and glass for proper
contact.
Increase contact using upper sash
adjustment bolt.
I Insufficient glass-to-door weatherstrip
contact
Check stabilizer and glass for proper
contact.
Increase contact using upper sash
G5M0503 adjustment bolt.
(This condition may cause wind noise and/or water
leakage.)
3) Adjust door glass so that it is aligned with door rearview I Window is not properly adjusted in
mirror gusset up-down/fore-aft direction. Adjust win-
dow. If necessary, move “B” channel for
regulator to eliminate window “tilt”.
I Gusset is not properly adjusted in
fore-aft direction. Adjust gusset after
loosing all bolts and nuts witch tighten-
ing it.
H5M0672A
41
5-2 [K100] DIAGNOSTICS
1. Door Glass

Door in fully 1) Glass rides over weatherstrip lip when door is closed. I Improper up-down and in-out glass
closed/ open posi- alignments
tion Adjust glass for up-down and in-out
alignments (incl. rear sash, upper stop-
per adjustment, etc.). If necessary, cor-
rect glass tilt by moving regulator “B”
channel.
G5M0505
(This condition increases wind/booming noise,
leakage and/or effort required to close door.)
2) Edge of glass contacts retainer when door is fully closed. I Improper glass-to-center pillar weath-
erstrip or excessive glass contact to
weatherstrip
Excessive adjusting in contact to weath-
erstrip causes rear edge of glass to tilt
inboard closer to center pillar. Adjust
rear sash adjustment bolt to reduce
glass contact to weatherstrip.
G5M0506
Raise or lower 1) Considerable effort or time is required to operate regulator. I Sliding resistance increased due to
window glass Standard operating effort: high stabilizer-to-glass contact pressure
I Entire up-down travel except for point 5 mm (0.20 in) below Reduce contact by mounting inner sta-
fully closed position: 29.4 N (3.0 kg, 6.6 lb) bilizer to inside of the car.
I Point 5 mm (0.20 in) below fully closed position: 45.0 N (4.5 I High glass-to-windshield contact
kg, 10.12 lb) pressure
Reduce contact using upper sash
adjustment bolt.
I Unequal contact adjustment stroke
between front and rear sashes
Set to equal stroke.
I Tilt of rear sash adjustment bolt
mounting bracket
Correct tilt of bracket so it is parallel to
inner panel.
G5M0507
42
1. Door Glass

Raise or lower 2) Center pillar weatherstrip is caught by rear window glass I Improper fore-aft or in-out alignment
window glass when glass is raised. of window glass
Lower regulator “B” channel to tilt win-
dow glass back.
G5M0508
3) Glass tilts forward by more than 2 mm (0.08 in). I Excessive glass contact pressure or
improper in-out alignment
1) Lower regulator “B” channel to tilt
glass rearward.
2) Reduce contact pressure using
upper sash adjustment bolt.
G5M0509
(Excessive tilt of glass forward is due to excessive
glass “contact” which causes reaction of center pillar weather-
strip.) Glass can be tilted forward due to increase in reaction of
shoulder weatherstrip or free play between sash and roller. Tak-
ing these symptoms into account, glass should be aligned.
43
2. Door Lock System
2. Door Lock System

No. Trouble Possible cause Remedy
Door cannot be opened by Disconnect outer handle rod. Connect firmly.
1 outer handle. (Door can be
opened by inner handle.)
Door cannot be opened by a. Joint of upper rod is disconnected. b. Connect firmly. Functionally nor-
2 inner handle. (Door can be Rear door child lock lever is set to lock mal.
opened by outer handle.) side.
Door does not open when a. Joint of lower rod is disconnected. b. Connect firmly. Remove rod from
outer or inner handle is oper- Lock is not released due to improper latch. Adjust rod so that lock knob
3
ated with inner lock knob set adjustment of lower rod. is set in “lock” position is locked.
to unlock position.
Door opens even when inner a. Lower rod joint is separated. b. Door is Same as a in No. 3. Same as a
lock knob is set to lock posi- not locked due to improperly adjusted lower in No. 3.
4
tion. (Keyless locking is rod.
impossible.)
Child lock lever will not come a. Inner handle fails to return completely. b. Refer to No. 6.
5
up. Joint of upper rod is disconnected.
Inner handle stops halfway. Contact of upper rod with inner handle Eliminate contact by bending
6
mounting case. upper rod properly.
Door cannot be locked or Joint of key lock rod is disconnected. Connect firmly.
7
unlocked by key.
Auto door-lock switch does Auto door-lock switch does not act due to Same as a in No. 3.
8 not act when inner lock knob improperly adjusted lower rod.
is pushed.
3. Power Window
Symptom
All windows do not The window of driver The window of The window of
move. side does not move. driver side does each passenger
not move “AUTO” sides does not
down. move.
Battery (1)
Fuse in fuse box (2)
Circuit breaker and relay (3)
Main switch (4) (1) (1) (1)
Sub switch of each passenger sides (2)
Motor of driver side (2) (2)
Motor of each passenger sides (3)
Regulator assembly of each windows (4)
Power supply line of main switch (5) (3) (3)
Ground line (6)
Haness and connector (7) (4) (4) (5)
(): Figures in a parenthesis refer to diagnostics procedures.
44
2. Door Lock System
2. Door Lock System

No. Trouble Possible cause Remedy
Door cannot be opened by Disconnect outer handle rod. Connect firmly.
1 outer handle. (Door can be
opened by inner handle.)
Door cannot be opened by a. Joint of upper rod is disconnected. b. Connect firmly. Functionally nor-
2 inner handle. (Door can be Rear door child lock lever is set to lock mal.
opened by outer handle.) side.
Door does not open when a. Joint of lower rod is disconnected. b. Connect firmly. Remove rod from
outer or inner handle is oper- Lock is not released due to improper latch. Adjust rod so that lock knob
3
ated with inner lock knob set adjustment of lower rod. is set in “lock” position is locked.
to unlock position.
Door opens even when inner a. Lower rod joint is separated. b. Door is Same as a in No. 3. Same as a
lock knob is set to lock posi- not locked due to improperly adjusted lower in No. 3.
4
tion. (Keyless locking is rod.
impossible.)
Child lock lever will not come a. Inner handle fails to return completely. b. Refer to No. 6.
5
up. Joint of upper rod is disconnected.
Inner handle stops halfway. Contact of upper rod with inner handle Eliminate contact by bending
6
mounting case. upper rod properly.
Door cannot be locked or Joint of key lock rod is disconnected. Connect firmly.
7
unlocked by key.
Auto door-lock switch does Auto door-lock switch does not act due to Same as a in No. 3.
8 not act when inner lock knob improperly adjusted lower rod.
is pushed.
3. Power Window
Symptom
All windows do not The window of driver The window of The window of
move. side does not move. driver side does each passenger
not move “AUTO” sides does not
down. move.
Battery (1)
Fuse in fuse box (2)
Circuit breaker and relay (3)
Main switch (4) (1) (1) (1)
Sub switch of each passenger sides (2)
Motor of driver side (2) (2)
Motor of each passenger sides (3)
Regulator assembly of each windows (4)
Power supply line of main switch (5) (3) (3)
Ground line (6)
Haness and connector (7) (4) (4) (5)
(): Figures in a parenthesis refer to diagnostics procedures.
44
1. Front Seat
1. Front Seat
H5M0701B
(1) Front seat ASSY (5) Outer slide rail ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Inner belt ASSY
T1: 23±5 (2.3±0.5, 16.6±3.6)
(3) Inner slide rail ASSY
T2: 29±7 (3.0±0.7, 21.7±5.1)
(4) Connect wire
T3: 52±10 (5.3±1.0, 38±7)
2
COMPONENT PARTS [C2A0] 5-3
2. Rear Seat
2. Rear Seat
A: SEDAN AND COUPE MODEL
H5M0915A
(1) Rear seat reinforcement (4) Rear cushion Tightening torque: N·m (kg-m, ft-lb)
(2) Hook
T1: 10±3 (1.0±0.3, 7.2±2.2)
(3) Backrest
T2: 25±7 (2.5±0.7, 18.1±5.1)
3
5-3 [C2B0] COMPONENT PARTS
2. Rear Seat
B: WAGON MODEL
H5M0916A
(1) Hinge bracket (RH) (8) Hinge Tightening torque: N·m (kg-m, ft-lb)
(2) Hinge bracket (RH) (9) Hinge cover
T1: 2±1 (0.2±0.1, 1.4±0.7)
(3) Backrest (LH) (10) Backrest center hinge
T2: 5.9±1.5 (0.6±0.15, 4.3±1.1)
(4) Striker (11) Belt pocket
T3: 10±3 (1.0±0.3, 7.2±2.2)
(5) Hinge bracket (LH) (12) Pad ASSY pocket
(6) Lock hinge (13) Hook T4: 25±7 (2.5±0.7, 18.1±5.1)
(7) Rear cushion
4
3. Front Seat Belt
3. Front Seat Belt
H5M0917A
(1) Adjuster anchor ASSY (5) Outer belt ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Through cover
T1: 13±3 (1.3±0.3, 9.4±2.2)
(3) Webbing guide
T2: 35±13 (3.6±1.3, 26±9)
(4) Inner belt ASSY
5
4. Rear Seat Belt
4. Rear Seat Belt
H5M0702B
(1) Webbing cover (RH) (6) Through cap (RH) Tightening torque: N·m (kg-m, ft-lb)
(2) Webbing cover (LH) (7) Through cap (LH)
T1: 13±3 (1.3±0.3, 9.4±2.2)
(3) Outer seat belt (LH) (8) Lap anchor cover (LH)
T2: 35±13 (3.6±1.3, 26±9)
(4) Center seat belt (9) Lap anchor cover (RH)
(5) Outer seat belt (RH)
6
5. Inner Accessories
5. Inner Accessories
H5M0918A
(1) Hook (3) Rearview mirror (5) Assist grip (retractable)

(2) Sun visor (4) Assist rail bracket (6) Assist grip (fixed)
7
6. Inner Trim
6. Inner Trim
H5M0703B
(1) Front pillar upper trim (9) Front pillar upper trim (17) Trim bracket
(2) Rear pillar upper trim (10) Rear quarter upper front trim (18) Rear quarter lower trim
(3) Rear pillar lower trim (11) Rear rail trim (19) Side sill rear upper cover
(4) Side sill rear upper cover (12) Rear quarter upper rear trim (20) Side sill rear lower cover
(5) Side sill rear lower cover (13) Rear gate trim (21) Center pillar lower trim
(6) Center pillar lower trim (14) Rear skirt trim (22) Side sill front lower cover
(7) Side sill front lower cover (15) Lamp cover (23) Front pillar lower trim
(8) Front pillar lower trim (16) Cover
8
1. Front Seat
1. Front Seat B: INSTALLATION

A: REMOVAL 1) While operating button (located on top of
backrest), lift headrest out by placing your hand
1) While operating button (located on top of between backrest and headrest.
backrest), lift headrest out with hand placed
between backrest and headrest.
H5M0704
H5M0704
2) Pull reclining lever back to fold backrest all the
way forward. Pull slide adjuster lever and move
2) Pull reclining lever back to fold backrest all the lower slide rail all the way backward.
way forward. While pulling slide adjuster lever, 3) Position seat in compartment and align the
move seat all the way forward. holes on the seat with the holes on the car body
3) Disconnect connector under driver’s seat. side.
4) Remove bolt cover at rear end of slide rail. 4) Secure the front of seat using inward and out-
5) Remove bolts securing seat rear. ward bolts (A) and (B) in that order.
5) While pulling slide adjuster lever, move seat all
the way forward.
6) Secure the rear of seat using inward and out-
ward bolts (C) and (D).
H5M0705
6) While pulling slide adjuster lever, slide seat all

the way back.
7) Remove bolts securing front of seat. H5M0706B
7) Connect connector under driver’s seat.

CAUTION:
Check that all lock plate pawls are completely
and equally inserted into the holes in the slide
rail brackets.
8) After installation, ensure that all mechanisms
operate properly and lock.
9) If any mechanism does not function properly,
loosen bolts (C) and (D), slide seat as required,
G5M0344 insert all lock plate pawls into holes in slide rail
brackets, and tighten bolts (C) and (D) in that
8) Remove front seat from vehicle. order.
CAUTION: 10) Install bolt cover on rear end of slide rail.
Be careful not to scratch seat when removing 11) Install headrest on backrest.
it from vehicle. NOTE:
Tighten bolts in the designated order.
9
2. Rear Seat
2. Rear Seat 4) Remove the bolt and then remove backrest (LH
side).
A: REMOVAL 5) Remove the bolt and then remove backrest (RH
side) from hinge bracket.
1. SEDAN AND COUPE MODEL
1) Remove bolts securing hinges (located at front
of cushion) to body.
2) Slightly raise front of cushion while pushing
down on cushion in the direction of “C”. With cush-
ion held in that position, move it forward until it is
unhooked.
B5M0333C
(A) Bolt (LH side)

(B) Bolt (Rh side)
(C) Hinge bracket
B: INSTALLATION
G5M0345 1. SEDAN AND COUPE MODEL
3) Remove bolts securing lower portion of back- 1) Before installing backrest, ensure that trim
rest to body. panel, insulator and seat belt are properly installed.
4) Lift rear seat backrest in direction “A” until it is 2) Transfer outer seat belt webbing to front of
released from upper hooks. backrest and fold backrest forward. Attach seat
belt webbing to upper hooks (2 places), and move
2. WAGON MODEL pillow in the direction of “B” until backrest is aligned
1) Remove bolts securing hinges (located at front with lower mounting holes in body.
of seat) to body.
G5M0348
G5M0350 3) Secure lower center and both sides of backrest

2) Pull strap (located in middle rear portion of to body with bolts.
cushion) to release lock. Lift cushion out and away
from body.
3) Pull knobs (located at each side of backrest’s
upper portion) up to release lock, and fold backrest
all the way forward.
10
2. Rear Seat
4) Slightly raise front section of cushion while 7) Install hinges to front of cushion and tighten
pushing down on cushion in the direction of “C”. with bolts. Check that lock properly engages.
With cushion held in that position, attach rear sec-
tion of cushion to hooks at lower frame location.
5) Secure front of cushion to body with bolts.
CAUTION:
I Before installing seat, ensure that seat belt is
placed on cushion.
I Confirm that winding of three-point type seat
belt can operate regularly.
G5M0353
8) Fold backrest onto cushion and overlap trunk

mat and mat at rear of backrest.
CAUTION:
I Do not allow center seat belt to get under
cushion when folding cushion.
I Ensure that side seat belt tongue is free from
cushion and trim panel.
G5M0345 I Lift front of cushion to ensure that cushion is
properly locked.
2. WAGON MODEL
1) Install hinge bracket to body.
2) Insert right backrest hinge pin into hole in
bracket. Tilt backrest backward until striker
engages with lock.
3) Secure right backrest center hinge to body
using a bolt.
G5M0352
4) Temporarily install left backrest side hinge to

body using a bolt, and fold backrest forward to the
floor.
5) Roll up mat (located at rear of left backrest),
and install center hinge using a bolt.
6) Tilt left backrest until striker engages with lock,
and tighten bolt.
11
3. Front Seat Belt
3. Front Seat Belt 2) Remove rear quarter trim.

1. OUTER BELT (sedan and wagon)
1) Remove through-anchor cover cap.
2) Remove shoulder anchor bolt.
3) Remove webbing guide.
G5M0640
3) Remove webbing guide.
G5M0354
4) Remove center lower pillar trim panel.

5) Remove front cover side plate.
6) Roll up floor mat at the bottom of center pillar.
7) Remove lap anchor bolt.
G5M0641
G5M0355
8) Remove belt retractor and outer belt. G5M0653

4) Remove anchor cover cap.
CAUTION: 5) Remove four bolts and then belt retractor and
I The left and right ELR’s are not mutually outer belt. Tightening torque:
interchangeable because different sensors are 6) Installation is in the reverse order of removal.
used.
I Be careful not to twist belts during installa- Tightening torque:
tion. T1: 13±3 N·m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
T2: 35±13 N·m (3.6±1.3 kg-m, 26±9 ft-lb)
2. OUTER BELT (coupe)
1) Remove rear seat cushion and backrest.
<Ref. to 5-3 [W2A1].>
G5M0642
12
4. Rear Seat Belt
CAUTION: 4. Rear Seat Belt

I The left and right ELR’s are not mutually
interchangeable because different sensors are A: REMOVAL AND INSTALLATION
used.
I Be careful not to twist belts during installa- 1. SEDAN AND COUPE MODEL
tion. 1) Remove rear cushion from body.
3. INNER BELT 2) Remove rear backrest from body.
3) Remove screw from lower side of rear quarter
Remove anchor nut. trim, and lift-up lower side of rear quarter trim.
4) Remove trim panel rear bracket upper.
5) Remove rear quarter trim.
6) Remove outer anchor bolts.
G5M0356
4. ADJUSTABLE SHOULDER ANCHOR

G5M0358
2) Remove lower center pillar trim. 7) Remove rear bolt from ELR.
3) Remove front and front pillar trim panel.
4) Remove adjustable shoulder anchor assembly.
G5M0359
G5M0357
8) Remove belt from outlet in rear quarter along
slit.
5) Installation is in the reverse order of removal. 9) Remove inner bolts which secure outer seat.
10) Remove washer from bolt, then remove bolt,
belt assembly, and anchor plate bracket.
11) Remove inner bolts (2 places) from center
seat.
G5M0360
12) Remove washer from bolt, and remove bolt,

belt assembly and anchor plate bracket.
13
4. Rear Seat Belt
CAUTION: 4. Rear Seat Belt

I The left and right ELR’s are not mutually
interchangeable because different sensors are A: REMOVAL AND INSTALLATION
used.
I Be careful not to twist belts during installa- 1. SEDAN AND COUPE MODEL
tion. 1) Remove rear cushion from body.
3. INNER BELT 2) Remove rear backrest from body.
3) Remove screw from lower side of rear quarter
Remove anchor nut. trim, and lift-up lower side of rear quarter trim.
4) Remove trim panel rear bracket upper.
5) Remove rear quarter trim.
6) Remove outer anchor bolts.
G5M0356
4. ADJUSTABLE SHOULDER ANCHOR

G5M0358
2) Remove lower center pillar trim. 7) Remove rear bolt from ELR.
3) Remove front and front pillar trim panel.
4) Remove adjustable shoulder anchor assembly.
G5M0359
G5M0357
8) Remove belt from outlet in rear quarter along
slit.
5) Installation is in the reverse order of removal. 9) Remove inner bolts which secure outer seat.
10) Remove washer from bolt, then remove bolt,
belt assembly, and anchor plate bracket.
11) Remove inner bolts (2 places) from center
seat.
G5M0360
12) Remove washer from bolt, and remove bolt,

belt assembly and anchor plate bracket.
13
4. Rear Seat Belt
13) Installation is in the reverse order of removal. I Ensure that seat belts are free from twisting
Ensure that seat belt is properly reeled on and off after installation.
after installation of ELR. I Ensure that tongues, buckles and belts are
properly placed on seat.
CAUTION:
I Be extremely careful not to confuse center
seat anchor plate with outer seat anchor plate
during installation.
I Ensure that seat belts are free from twisting
after installation.
I Ensure that tongues, buckles and belts are
properly placed on seat.
2. WAGON MODEL
1) Raise rear cushion.
2) Remove rear backrest from body.
3) Remove shoulder anchor cover and anchor
bolt.
4) Remove lower portion of rear quarter trim.
5) Remove lap anchor cover and bolt.
G5M0361
6) Remove 7/16-20 UNF nuts which secure ELR

and remove ELR.
CAUTION:
Remove outer seat belt and center seat belt in
similar manner used to remove those from
Sedan.
G5M0362

Ensure that seat belt is properly reeled on and off
after installation of ELR.
CAUTION:
I Be extremely careful not to confuse center
seat anchor plate with outer seat anchor plate
during installation.
14
5. Inner Trim Panel
5. Inner Trim Panel 3. REAR QUARTER PILLAR UPPER TRIM

PANEL (WAGON)
1) Set rear seat cushion up.
1. FRONT PILLAR UPPER TRIM PANEL 2) Remove rear seat backrest.
1) Remove center pillar lower trim panel. 3) Remove rear quarter lower trim.
2) Remove seat belt anchor bolts. 4) Remove rear rail trim.
3) Pry pawls off body flange of front pillar upper 5) Remove rear quarter upper front trim.
trim panel using screwdriver. 6) Remove rear quarter upper rear trim.
4) Remove clips which hold front pillar upper trim
panel, and lift trim panel out by moving it toward
the compartment.
G5M0365

G5M0363
CAUTION:
Be sure to securely hook pawls of rear quarter
5) Installation is in the reverse order of removal. pillar trim panel on body flange.
CAUTION: 4. REAR QUARTER LOWER TRIM PANEL
Be sure to securely hook pawls of front pillar (WAGON)
upper trim panel on body flange.
1) Remove luggage cover.
2. REAR PILLAR UPPER TRIM PANEL 2) Set rear seat cushion up.
(SEDAN) 3) Remove rear seat backrest.
4) Remove rear skirt trim.
1) Remove rear seat cushion and backrest.
5) Remove clip and screw then disconnect con-
2) Remove tapping screw from rear pillar lower nector (RH side).
trim panel, and remove trim panel by sliding it for- 6) Remove rear seat belt lower anchor then
ward. remove rear quarter lower trim.
3) Remove front pillar upper trim end.
4) Pry the pawl off front end using screwdriver.
5) Remove clips which hold rear pillar upper trim,
and remove trim panel by sliding it forward.
H5M0707

CAUTION:
G5M0364 Be careful not to ride trim panel over harness,
insulators, etc.
5. FLOOR MAT
CAUTION:
Be sure to securely hook pawls of rear pillar Supplemental Restraint System “Airbag” Air-
upper trim panel on body flange. bag system wiring harness is routed near floor
mat.
15
5. Inner Trim Panel
CAUTION: 9) Remove four clips under front seat.

I All Airbag system wiring harness and con- 10) Remove four clips in toe board area.
nectors are colored yellow. Do not use electri-
NOTE:
cal test equipment on these circuit.
I Be careful not to damage Airbag system wir- When pulling out edge, do not pull mat alone; pull
ing harness when servicing floor mat. mat together with edge. Pry off two steel clips on
side sill front cover and one on side sill rear cover
1) Remove front seats. using screwdriver.
2) Remove rear seat cushion.
3) Remove center tray, indicator cover, cover 11) Remove mat hook.
assembly, and console box, depending on the 12) Remove mat from toe board area.
specifications.
4) Remove front pillar lower trim panel.
5) Remove center pillar lower trim panel.
6) Remove three clips under rear seat cushion.
7) Remove rear cover side plate and rear pillar
lower trim.
8) Pull out edge in the groove of side sill cover.
G5M0368
13) Remove mat from heater unit.

14) Roll mat, and take it out of opened rear door.
NOTE:
I Secure mat firmly with hook and velcro tape.
G5M0367
I Insert mat edge firmly into the groove of side sill
cover.
16
1. Instrument Panel
1. Instrument Panel
H5M0931A
(1) Pad & frame (12) Pocket (23) Ash tray

(2) Grille side (D) (13) Panel center (24) Console box
(3) Front def. grille (14) Center pocket lid (25) Console pocket
(4) Grille side (P) (15) Grille center (26) Rear console BRKT
(5) Grille vent (P) (16) Cup holder (27) Front cover
(6) Glove box panel (17) Side pocket
(7) Glove box lid (18) Lower cover ASSY Tightening torque: N·m (kg-m, ft-lb)
(8) Knob (19) Meter visor T: 7±1 (0.7±0.1, 5.1±0.7)
(9) Instrument panel center console (20) Grille vent (D)
(10) BRKT (Radio) (21) Console cover
(11) Center console cover (22) Console lid
2
1. Instrument Panel
1. Instrument Panel 6) Disconnect data link connector (A) from lower

cover.
A: REMOVAL
Airbag system wiring harness is routed on steering
support beam.
CAUTION:
I All Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
I Be careful not to damage Airbag system wir-
ing harness when servicing the instrument
panel. S5M0045A
1) Disconnect GND cable from battery.

7) Remove knee panel.
2) Remove shift knob (MT model).
3) Remove console cover (A) and front cover (B).
S5M0046
S5M0042A 8) Remove glove box.

4) Remove console box.
S5M0047A
S5M0043 9) Remove center panel and disconnect connec-

tor.
5) Remove lower cover and then disconnect con-
10) Remove audio.
nector.
S5M0048A
S5M0044A
3
1. Instrument Panel
11) Remove two bolts and lower steering column. 13) Disconnect temperature control cable and
mode control cable from heater unit then discon-
nect recirc control cable from intake unit.
NOTE:
Do not move switch and link when installing.
G5M0278
12) Set temperature control switch to “FULL

HOT”, mode selector switch to “DEF” position and
recirc switch to “FRESH” position.
S5M0049A
4
1. Instrument Panel
14) Disconnect harness connectors and then remove the installing bolts and nuts.
CAUTION:
Be sure to hold socket section and not harness when disconnecting.
NOTE:
Put matching mark, if necessary, for easy reassembly.
S5M0050A
5
1. Instrument Panel
15) Remove front defroster grille and two bolts. B: INSTALLATION

Installation is in the reverse order of removal.
CAUTION:
I Be careful not to snag the harness.
I Make sure to connect harness connectors.
I Take care not to scratch the instrument panel
and related parts.
NOTE:
When setting instrument panel into position, push
two pins into grommet on body panel.
S5M0051
16) Remove instrument panel carefully from the

body.
CAUTION:
I Take care not to scratch the instrument panel
and related parts.
I When storing removed instrument panel with
passenger airbag module, place it standing up
on the floor.
S5M0052A
G5M0602
6
1. SRS Airbag
1. SRS Airbag
H5M0932A
(1) Combination switch ASSY with (6) Airbag control module Tightening torque: N·m (kgf-m, ft-lb)
roll connector (7) Airbag main harness
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
(2) TORXTbolt T30 (8) Front sub sensor harness (RH)
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Airbag module ASSY (Driver) (9) Front sub sensor harness (LH)
T3: 10±2 (1.0±0.2, 7.2±1.4)
(4) Airbag module ASSY (Passen- (10) Front sub sensor (RH)
ger) (11) Front sub sensor (LH) T4: 20±4 (2.0±0.4, 14.5±2.9)
(5) TORXT bolt T40 T5: 25±2 (2.5±0.2, 18.1±1.4)
2
1. General
1. General I When checking the system, be sure to use a

digital circuit tester. Use of an analog circuit tester
A: PRECAUTION may cause the airbag to activate erroneously. Do
I If any of the airbag system parts such as not directly apply the tester probe to any connec-
sensors, airbag module, airbag control module and tor terminal of the airbag. When checking, use a
harness are damaged or deformed, replace with test harness.
new genuine parts.
G5M0293
G5M0291
I When servicing, be sure to turn the ignition

switch off, disconnect the negative (−) battery ter-
minal then the positive (+) terminal in advance, and
wait for more than 20 seconds before starting
work.
G5M0292
G5M0294
3
1. General
I Do not drop the airbag modulator parts, subject I Install the wire harness securely with the speci-
it to high temperatures over 90°C (194°F), or apply fied clips so as to avoid interference or jamming
oil, grease, or water to it; otherwise, the internal with other parts.
parts may be damaged and its reliability greatly
lowered.
G5M0297
I Before connecting the airbag system to ground,

make sure that the grounding terminal is free from
paint and contamination.
I Do not allow water or oil to come in contact with
the connector terminals. Do not touch the connec-
tor terminals.
G5M0295
I If any damage or open is found on the SRS air-

bag system wire harness, do not attempt to repair
using soldering, etc. Be sure to replace the faulty G5M0298
harness with a new genuine part.
I When cpnnecting or disconnecting airbag
connector, make sure ignition switch is OFF.
G5M0296
4
SERVICE PROCEDURE [W2F2] 5-5
2. Inspection and Replacement Standards
2. Inspection and Replacement D: AIRBAG CONTROL MODULE

Standards 1. INSPECTION STANDARD
A: VEHICLES WHICH BECOME I A vehicle damaged in a collision (regardless of
whether or not airbag is deployed).
INVOLVED IN A COLLISION I The designated trouble code is output during
If the vehicle equipped with an SRS airbag sys- self-diagnosis. <Ref. to 5-5 [T4A0].>
tem is damaged in a collision, the airbag sys-
tem parts must be checked and replaced in 2. REPLACEMENT STANDARD
accordance with the following standards: I Control module is cracked or deformed.
I After faulty parts are replaced, the warning I Mounting bracket is cracked or deformed.
light operation must be checked. I Connector is scratched or cracked.
I When the ignition switch is turned ON, it I Control module dropped to the floor/ground.
lights up for 8 seconds and then it goes out for I Control module determined as faulty during
at least 30 seconds. diagnostics.
I The trouble code stored in memory must be I Airbag is deployed.
erased after the check.
E: COMBINATION SWITCH
B: AIRBAG MODULE (DRIVER AND
1. INSPECTION STANDARD
PASSENGER)
I A vehicle damaged in a collision (regardless of
1. INSPECTION STANDARD whether or not airbag is deployed).
I The vehicle damaged in a collision (regardless I The designated trouble code is output during
of whether or not airbag is deployed). self-diagnosis. <Ref. to 5-5 [T4A0].>
I The designated trouble code is output during
self-diagnosis. <Ref. to 5-5[T4A0].> 2. REPLACEMENT STANDARD
I Combination switch or steering roll connector is
2. REPLACEMENT STANDARD deformed or cracked.
I Airbag is deployed.
I The pad surface is scratched or cracked. F: STEERING WHEEL
I Harness and/or connector is deformed or 1. INSPECTION STANDARD
cracked, their circuits are broken, lead wire is
exposed, etc. I A vehicle damaged in a collision (regardless of
I Mounting bracket is cracked or deformed. whether or not airbag is deployed).
I The module surface is fouled with foreign mat-
ter. (grease, oil, water, cleaning solvent, etc.)
2. REPLACEMENT STANDARD
I Airbag module dropped to the floor/ground. I Check steering wheel insert for cracks or defor-
I Airbag module determined as faulty during self- mities.
diagnosis. I Check to ensure that new airbag module is prop-
erly installed in steering wheel
C: MAIN HARNESS I After installing airbag module, check to ensure
that it is free of interference with steering wheel
1. INSPECTION STANDARD and that clearance between the two is equal at all
I A vehicle damaged in a collision (regardless of points.
whether or not airbag is deployed).
self-diagnosis. <Ref. to 5-5 [T4A0].>
2. REPLACEMENT STANDARD
I Harness circuit is broken, lead wire is exposed,
corrugated tube is cracked, etc.
I Connector is scratched or cracked.
self-diagnosis.
B5M0095
5
5-5 [W2G1] SERVICE PROCEDURE
2. Inspection and Replacement Standards
G: STEERING COLUMN ASSEMBLY 2. REPLACEMENT STANDARD

1. INSPECTION STANDARD I Bracket is deformed.
I Housing is cracked or deformed.
I A vehicle damaged in a collision (regardless of I The label (that identifies the manufacturing num-
whether or not airbag is deployed). ber) is peeled or deteriorated.
I Harness circuit is broken, lead wire is exposed,
2. REPLACEMENT STANDARD corrugated tube is cracked, etc.
I Check to ensure that clearance of expand plate I Front sub sensor determined as faulty as a
on steering column under side is within specifica- result of Diagnostics.
tions. I Airbag is deployed.
I Front sub sensor dropped to the floor/ground.
Clearance of expand plate: L
More than 15 mm (0.59 in)
S5M0213A
H: FRONT SUB SENSOR

1. INSPECTION STANDARD
I Check the front section (Refer to shaded area of
vehicle in figure) for damage, regardless of
whether or not airbag is deployed.
G5M0311

self-diagnosis. <Ref. to 5-5 [T4A0].>
6
3. Airbag Module
3. Airbag Module I Do not check airbag module (driver side and

passenger side) continuity with airbag
A: REMOVAL AND INSTALLATION removed from the vehicle body.
CAUTION:
I The airbag module (driver side and passen-
ger side) must not be disassembled. The airbag
module cannot be used again once inflated.
G5M0302
I Replace airbag module (driver side and pas-

senger side) with a new one, should any of the
following conditions develop:
G5M0299
I Pad surface is scratched or cracked.
I When removing and installing the airbag I Connector harness is damaged.
module (driver side and passenger side), the I Inflator side structure of module is
operator should stand, as much as possible, cracked or deformed.
on the side of the airbag module. I Module is excessively stained with water,
oil, etc.
I Module was accidentally dropped.
I When storing a removed airbag module
(driver side and passenger side), be sure to
place it in parallel with floor with the pad facing
up. Do not place it against a wall, or place any-
thing on the pad; otherwise, a dangerous con-
dition may be created if the module malfunc-
tions.
G5M0300
I After removal, the airbag module (driver side

and passenger side) should be kept away from
heat and light sources, and stored on a clean,
flat surface to prevent from any damage to its
lower structure.
G5M0301
7
3. Airbag Module
G5M0604
1. DRIVER SIDE
1) Set front wheels in straight ahead position.
2) Turn ignition switch off.
3) Disconnect ground cable from battery and wait
for at least 20 seconds before starting work.
8
3. Airbag Module
4) Using TORXT BIT T30, remove two TORXT 5) Remove seven bolts and then carefully remove
bolts. airbag module.
H5M0662A S5M0215
5) Disconnect airbag connector on back of airbag 6) Refer to “CAUTION:” for handling of a removed
module. <Ref. to 5-5 [M2F2].> airbag module. <Ref. to 5-5 [W3A0].>
CAUTION:
Do not allow harness and connectors to inter-
fere or get caught with other parts.
H5M0664
6) Refer to “CAUTION:” for handling of a removed

airbag module. <Ref. to 5-5 [W3A0].>
CAUTION:
Do not allow harness and connectors to inter-
fere or get caught with other parts.
2. PASSENGER SIDE
3) Remove glove box. <Ref. to 5-4 [W1A0].>
4) Disconnect airbag connector. <Ref. to 5-5
[M2F2].>
S5M0214
9
4. Main Harness
4. Main Harness 8) Disconnect front sub sensor connector from air-

bag main harness.
A: REMOVAL AND INSTALLATION 9) Detach clips from steering support beam and
remove main harness.
3) Remove lower cover. <Ref. to 5-4 [W1A0].>
4) Disconnect airbag connector (AB3) and (AB8)
below steering column. <Ref. to 5-5 [M2F2].>
CAUTION:
Do not reconnect airbag connector at steering
column until main harness are securely re-in-
stalled.
H5M0933A
G5M0312
5) Remove instrument panel. <Ref. to 5-4

[W1A0].>
6) Disconnect connector from airbag control mod-
ule.
S5M0216
7) Disconnect body harness connector (B31) from

connector (AB1).
S5M0217A
10
5. Airbag Control Module
5. Airbag Control Module 3) Remove lower cover. <Ref. to 5-4 [W1A0].>

4) Disconnect airbag connector (AB3) and (AB8)
A: REMOVAL AND INSTALLATION below steering column.
CAUTION: CAUTION:
I Do not disassemble the airbag control mod- Do not reconnect airbag connector at steering
ule. column until airbag control module is securely
re-installed.
G5M0322
G5M0312
I If the airbag control module is deformed, or
5) Remove instrument panel console. <Ref. to 5-4
if water damage is suspected, replace the air-
[W1A0].>
bag control module with a new genuine part. 6) Disconnect connector from airbag control mod-
ule.
7) Using T40 TORXT bit (Tamper resistant type),
remove four TORXT bolts in numerical sequence
shown in figure. Discard the old TORXT bolts.
CAUTION:
Use new TORXT bolts during re-assembly.
G5M0323
I After removal, keep the airbag control mod-

ule on a dry, clean surface away from heat and
light sources, and moisture and dust.
S5M0219A
G5M0324

11
6. Combination Switch
6. Combination Switch 7) Using steering puller, remove steering wheel.

CAUTION:
A: REMOVAL Do not allow connector to interfere when
1) Turn ignition switch off. removing steering wheel.
Disconnect airbag connector (AB3) and (AB8)
below steering column.
CAUTION:
column until combination switch is securely re-
installed.
G5M0332
8) Remove steering column covers.

9) Removing three retaining screws, remove com-
bination switch.
G5M0312
4) Disconnect combination switch connectors

from body harness connector.
5) Set front wheels in straight ahead position.
Using T30 TORXT bit, remove two TORXT bolts.
S5M0220
B: ADJUSTMENT
1. CENTERING ROLL CONNECTOR
Before installing steering wheel, make sure to cen-
ter roll connector built into combination switch.
1) Make sure that front wheels are positioned
straight ahead.
2) Install steering gearbox, steering shaft and
H5M0662A combination switch properly. Turn roll connector
pin (A) clockwise until it stops.
6) Disconnect airbag connector on back of airbag
3) Then, back off roll connector pin (A) approxi-
module. Remove airbag module, and place it with
mately 2.65 turns until “G” marks aligned.
pad side facing upward. <Ref. to 5-5 [W3A0].>
H5M0663B
H5M0664
12
7. Front Sub Sensor
C: INSTALLATION 7. Front Sub Sensor

Failure to do this might damage roll connector.
CAUTION:
1) Before installing combination switch, check to
I If the front end of the vehicle body is dam-
ensure that combination switch is off and front
wheels are set in the straight ahead position. aged by a collision, be sure to check the left
2) Install column cover and center roll connector. and right front sub sensors, even if the airbag
<Ref. to 5-5 [W6B1].> was not inflated. If any damage to the sensor or
3) Install steering wheel in neutral position. Care- any deformation of the sensor mount is found,
fully insert roll connector pin (A) into hole on steer- replace with a new genuine part.
ing wheel.
NOTE:
If steering wheel angle requires fine adjustment,
adjust tie-rod. <Ref. to 4-3 [W3F0].>
G5M0291
I When painting or performing sheet metal

work on the front part of vehicle body, includ-
ing the front wheel apron, front fender and
H5M0663B front side frame, take utmost care not to apply
4) Install airbag module and lower cover in the dryer heat, painting mist, or the flame of the
reverse order of removal. welding burner directly to the front sub sen-
sors and wire harness of the airbag system.
G5M0310
1. FRONT SUB SENSOR HARNESS

13
7. Front Sub Sensor
C: INSTALLATION 7. Front Sub Sensor

Failure to do this might damage roll connector.
CAUTION:
1) Before installing combination switch, check to
I If the front end of the vehicle body is dam-
ensure that combination switch is off and front
wheels are set in the straight ahead position. aged by a collision, be sure to check the left
2) Install column cover and center roll connector. and right front sub sensors, even if the airbag
<Ref. to 5-5 [W6B1].> was not inflated. If any damage to the sensor or
3) Install steering wheel in neutral position. Care- any deformation of the sensor mount is found,
fully insert roll connector pin (A) into hole on steer- replace with a new genuine part.
ing wheel.
NOTE:
If steering wheel angle requires fine adjustment,
adjust tie-rod. <Ref. to 4-3 [W3F0].>
G5M0291
I When painting or performing sheet metal

work on the front part of vehicle body, includ-
ing the front wheel apron, front fender and
H5M0663B front side frame, take utmost care not to apply
4) Install airbag module and lower cover in the dryer heat, painting mist, or the flame of the
reverse order of removal. welding burner directly to the front sub sen-
sors and wire harness of the airbag system.
G5M0310
1. FRONT SUB SENSOR HARNESS

13
7. Front Sub Sensor
4) Disconnect airbag connector (AB3) and (AB8) 8) Remove wiring harness clips.
below steering column.
CAUTION:
column until front sub sensors are securely re-
installed.
G5M0315
9) Remove grommet and then detach front sub

sensor harness.
G5M0312
5) Remove front side sill cover and then discon-

nect front sub sensor connector. <Ref. to 5-5
[M2F2].>
G5M0316
2. FRONT SUB SENSOR ASSEMBLY

B5M0517 3) Remove front wheel and mud guard.
4) Disconnect connector from front sub sensor
6) Remove front wheel and mud guard. assembly. <Ref. to 5-5 [M2F3].>
7) Disconnect connector from front sub sensor
assembly. <Ref. to 5-5 [M2F3].>
B5M0518
B5M0518
14
7. Front Sub Sensor
5) Remove front sub sensor.
B5M0519
15
5-5 SERVICE PROCEDURE
MEMO:
16

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5-1 [S1A0] SPECIFICATIONS AND SERVICE DATA

2. Body Datum Points

B: LUGGAGE COMPARTMENT AND ROOM

D: DATUM POINT LOCATION

3. Datum Dimensions NOTE:

C: DOORS AND REAR QUARTER

D: FRONT WINDSHIELD AND REAR WINDOW

E: TRUNK LID AND REAR GATE

4. Datum Points and Dimensions Concerning On-Board Aiming

1. Front Hood and Hood Lock

(1) Weatherstrip (10) Harness (19) Shutting ASSY (RH)

6. Steering Support Beam

(1) Bracket Tightening torque: N·m (kg-m, ft-lb)

(1) Guard pipe Tightening torque: N·m (kg-m, ft-lb)

1. Hood 2) Remove bolts which secure lock assembly to

3) Detach front hood from hinges.

2) Remove the left and right torsion bars.

2) Remove the left and right torsion bars.

8) Installation is in the reverse order of removal.

4. TRUNK LID OPENER

3. Fuel Flap 4. Front Bumper

2) Installation is in the reverse order of removal.

2. FUEL FLAP OPENER

8) Remove bolts from lower side of bumper.

5) Detach fuel lock holder by turning it.

3. Fuel Flap 4. Front Bumper

2) Installation is in the reverse order of removal.

2. FUEL FLAP OPENER

8) Remove bolts from lower side of bumper.

5) Detach fuel lock holder by turning it.

9) Remove bolts (engine compartment side) from 5. Rear Bumper

10) Remove turn signal light connector.

4) Remove bolts from bumper stay.

12) Installation is in the reverse order of removal.

9) Remove bolts (engine compartment side) from 5. Rear Bumper

10) Remove turn signal light connector.

4) Remove bolts from bumper stay.

12) Installation is in the reverse order of removal.

6. Coating Method for PP

7. Repair Instructions for Colored PP Bumper

A: MINOR DAMAGE CAUSING ONLY A CHANGE IN THE LUSTRE OF THE

B: DEEP DAMAGE CAUSED BY SCRATCHING FENCES, ETC.

C: DEEP DAMAGE SUCH AS A BREAK OR HOLE THAT REQUIRES FILLING

Process Process name Job contents

Process Process name Job contents

Process Process name Job contents

8. Side Protector NOTE:

4) Installation is in the reverse order of removal.

9. Front Fender NOTE:

6) Remove body protector. (This step may be

10. Mud Guard and Rear Arch 11. Cowl Panel

2) Remove arch protectors.

10. Mud Guard and Rear Arch 11. Cowl Panel

2) Remove arch protectors.

12. Molding and Retainer 13. Front Grille

12. Molding and Retainer 13. Front Grille

14. Sunroof 5) Close sunroof and remove nuts.

6) Remove sunroof panel.

4) Remove relay by pulling it out.

4) Disconnect connector between body harness B: INSTALLATION

5) Loosen two mounting bolts near motor. (Do not G5M0198

6) Remove six bolts, and four adjusting nuts. G5M0199

3) Tighten adjusting nut (that is, set frame at high-

7) Remove sunroof frame.